Manual de Servicio Rodius/Stavic

GASOLIN ENGINE
CONTENTS
GENERAL INFORMATION................... SECTION 1A
ENGINE MECHANICAL ...................... SECTION 1B
ENGINE COOLING ............................... SECTION 1D
ENGINE ELECTRICAL ..........................SECTION 1E
ENGINE CONTROLS ............................ SECTION 1F
ENGINE INTAKE & EXHAUST ............. SECTION 1G
SECTION
1A
GENERAL
INFORMATION
1A-1
SECTION
00 1A
GENERAL INFORMATION
Table of Contents
DESCRIPTION AND OPERATION .................................. 1A-2
Cleanliness and care ................................................. 1A-2
On-engine service ..................................................... 1A-2
COMPONENT LOCATOR ............................................... 1A-3
Front view .................................................................. 1A-3
Side view .................................................................... 1A-4
DIAGNOSTIC INFORMATION AND PROCEDURE ....... 1A-5
Oil leak diagnosis ....................................................... 1A-5
Compression pressure test ....................................... 1A-6
Cylinder pressure leakage test ................................. 1A-8
General diagnosis .................................................... 1A-10
SPECIFICATIONS ......................................................... 1A-15
Engine specifications ............................................... 1A-15
Performance curve .................................................. 1A-16
SPECIAL TOOLS AND EQUIPMENT ........................... 1A-17
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
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1A-2
DESCRIPTION AND OPERATION

CLEANLINESS AND CARE
ON-ENGINE SERVICE
An automobile engine is a combination of many

machined, honed, polished and lapped surfaces with
tolerances that are measured in the ten-thousanths of
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating of
enigne oil should be applied to friction areas during
assembly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop practice
even if not specifically stated.
Caution
Disconnect the negative battery cable before removing
or installing any electrical unit, or when a tool or
equipment could easily come in contact with exposed
electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle.
The ignition must also be in LOCK unless otherwise
noted.
Whenever valve train components are removed for

service, they should be kept in order. They should be
installed in the same locations, and with the same mating surfaces, as when they were removed.
Notice
Any time the air cleaner is removed, the intake opening
should be covered. This will protect against accidental
entrance of foreign material, which could follow the
intake passage into the cylinder and cause extensive
damage when the engine is started.
Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or
other electrical parts.
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GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-3
COMPONENT LOCATOR
FRONT VIEW
1. HFM sensor
9. Valve tappet
16. Engine mounting bracket
2. Intake air duct
10. Injector
17. Starter
3. Resonance flap
11. Exhaust valve
18. Crankcase
4. Cylinder head cover
12. Intake manifold
19. Oil pump sprocket
5. Exhaust camshaft
13. Connecting rod
20. Oil strainer
6. Intake camshaft
14. Exhaust manifold
21. Oil pan
7. Cylinder head
15. Crankshaft
22. Drain plug
8. Spark plug connector
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
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1A-4
SIDE VIEW
23. Camshaft adjuster
27. Oil pump drive chain
24. Cooling fan and viscous clutch
28. Oil return pipe
25. Piston
29. Timing chain
26. Flywheel of drive plate
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GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-5
DIAGNOSTIC INFORMATION AND PROCEDURE

OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following procedures
may help you in locating and repairing most leaks.
Finding the Leak

1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
Black Light and Dye Method

A dye and light kit is available for finding leaks, Refer
to the manufacturer's directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
Repairing the Leak

Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must
be determined in order for it to be repaired properly. If
a gasket is replaced, but the sealing flange is bent, the
new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to repair a
leak, check for the following conditions and correct them
as they may cause a leak.
Gaskets
The fluid level/pressure is too high.
The crankcase ventilation system is malfunctioning.
The fasteners are tightened improperly or the
threads are dirty or damaged.
4.1 Clean the area well.
The flanges or the sealing surface is warped.
4.2 Dry the area.
There are scratches, burrs or other damage to the

sealing surface.
4.3 Operate the vehicle for several miles at normal

operating temperature and varying speeds.
4.4 After operating the vehicle, visually check the
suspected component.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating
conditoins.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the
white powder surface to the source.
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
The gasket is damaged or worn.

There is cracking or porosity of the component.
An improper seal was used (where applicable).
Seals
The seal bore is damaged (scratched, burred or
nicked).
The seal is damaged or worn.
Improper installation is evident.
There are cracks in the components.
The shaft surface is scratched, nicked or damaged.
A loose or worn bearing is causing excess seal wear.
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1A-6
COMPRESSION PRESSURE TEST
1. Compression pressure tester
3. Adaptor
2. Diagram sheet
4. Sealing cone
Standard Service Data

Application
M162 Engine
Compression ratio
10 : 1
Normal engine temperature

Normal compression pressure
Permissible pressure difference between
individual cylinders
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80C (176F)
Normal
Min. 10 bar, Max. 14 bar
Optimized fuel pressure
Min. 6 bar, Max. 10 bar

Max. 1.5 bar
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-7
Tools Required
A9912 0012B
(001 589 76 21 00)
Compression Pressure Tester
Measuring Procedure
1. Warm the engine up to normal operating temperature.
2. Remove the spark plugs using the spark plug wrench.
3. Place the diagram sheet to compression pressure
tester A9912 0012B (001 589 76 21 00).
4. Connect the adaptor to compression pressure tester
A9912 0012B (001 589 76 21 00) and install it into
the spark plug hole.
6. Compare the measurements of compression pressure

tester A9912 0012B (001 589 76 21 00) with the
specifications.
7. Measure the compression pressure of the other
cylinders in the same way.
8. If measured value is not within the specifications,
perform the cylinder pressure leakage test.
Notice
Discharge the combustion residues in the
cylinders before testing the compression
pressure.
Apply the parking brake before cranking the
engine.
5. Crank the engine approx. eight revolutions by using

the start motor.
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
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1A-8
CYLINDER PRESSURE LEAKAGE TEST
1. Engine oil filler cap
3. Cylinder pressure leakage tester with connecting hose
2. Vibration damper
Permissible Pressure Leakage

At whole engine
Max. 25 %
At valve and cylinder head gasket
Max. 10 %
At piston and piston ring
Max. 20 %
Cylinder Number by Mark on Vibration Damper at TDC

TDC Mark
Cylinder number
OT (TDC)
a (120)
b (240)
1, 6
2, 5
3, 4
Universal Tool
Cylinder pressure leakage tester
Bosch, EFAW 210A

Sun, CLT 228
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GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-9
Leakage Test
1. Warm the engine up to normal operating temperature.
2. Disconnect the negative battery cable.
3. Remove the spark plugs.
4. Check the coolant level by opening the coolant
reservoir cap and replenish if insufficient.
5. Open the engine oil filler cap.
6. Connect the tester to air pressure line and adjust the
scale of tester.
7. Install the connecting hose to spark plug hole.
8. Position the piston of No.1 cylinder at TDC by rotating
the crankshaft.
9. Connect the connecting hose to tester and measure the

leakage volume after blowing up 5 bar of compressed
air.
Notice
Measure the leakage volume in the completely
opening condition of throttle valve by pulling the
acceleration cable.
10. Perform the pressure test according to the firing order.
Notice
Firing Order: 1 - 5 - 3 - 6 - 2 - 4.
11. Compare the leakage pressure with the specifications.
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
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1A-10
GENERAL DIAGNOSIS
Condition
Hard starting
(With normal
cranking)
Replace the fuse.
Faulty spark plug.
Clean, adjust the plug gap or

replace.
Electric leakage at the high

tension cable.
Replace the cable.
Poor connection of the high

tension cable or lead wires.
Replace the cable or wires.
Improper ignition timing.
Adjust the ignition timing.
Faulty ignition coil.
Replace the ignition coil.
Lock of fuel in the fuel tank.
Feed the fuel.
Dirty or clogged fuel filter.
Replace the filter.
Clogged fuel pipe.
Clean the fuel pipe.
Malfunction of the fuel pump.
Replace the fuel pump.
Malfunction of the fuel injector.
Replace the injector.
The foreign material in the fuel

tank.
Clean the fuel tank.
Poor tightening spark plug.
Tighten to the specified torque.

Compression
Cracked cylinder head gasket.
Replace the gasket.
Inadequate the valve clearance.
Adjust the clearance.
Leakage of the valve clearance.
Repair the valve.
Interference of the valve stem.
Replace the valve or the valve

guide.
Low elasticity or damage of the

valve spring.
Replace the valve spring.
Abnormal interference of pistons

and cylinders.
Replace the piston ring.
Excessive wear of pistons, rings,

or cylinders.
Replace the ring or the piston and

boring or replace the cylinder.
Broken timing belt.
Replace the belt.
Loosening, damage or leakage of

the vacuum hose.
Connect the hose correctly or

replace it.
Leakage of intake system.
Replace intake system.
Decline of compression pressure
Refer to above in this page.
Malfunction of
ignition system
Faulty spark plug.
Adjust or replace the spark plug.
Electric leakage or poor connection of the high tension cable.
Connect the cable correctly or

replace it.
Others
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Correction
Faulty fuse.
Malfunction of ignition system
Malfunction of fuel
system
Lack of engine
power
Probable Cause
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-11
General Diagnosis (Contd)

Condition
Lack of engine
power
Rough engine
idling
Clogged fuel pipe.
Clean the pipe.
Clogged or contaminated fuel filter.
Replace the filter.
Others
Clogged exhaust system.
Check and repair the system.
Clogged or contaminated air

cleaner element.
Clean or replace the air cleaner

element.
Leak of the intake manifold gasket.
Replace the gasket.
Dragging brakes.
Repair or replace the brakes.
Refer to Page 1A-6.
Refer to Page 1A-6.
Malfunction of fuel
system
Clogged fuel pipe.
Clean the pipe.
Replace the filter.
Malfunction of the fuel pressure

regulator.
Replace the regulator.
Malfunction of the spark plug.
Electric leakage or poor connection

of the high tension cable.

replace it.
Poor ignition timing.
Malfunction of the ignition coil.

cleaner element.

element.
Replace the gasket.
Poor connection or damage or

leakage of the vacuum hose.

replace it.
Refer to Page 1A-6.
Refer to Page 1A-6.
Poor spark plug or Poor adjustment

of the plug gap.
Replace the plug or adjust the gap.


replace it.
Malfunction of the air cleaner

system.

system.
Replace the gasket.
Others
Others
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
Correction
Malfunction of fuel
system
Engine hesitate
(Upon pressing
accelerating
pedal, the engine
makes delayed
response This
situation is
remarkable when
cruising or
starting.)
Probable Cause
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1A-12

Condition
Engine surging
(Engine power
makes
fluctuation in a
fixed speed and
speed changes
without
operating the
accelerating
pedal.)
Overheat
Refer to Page 1A-6.
Refer to Page 1A-6.
Malfunction of
fuel system
Clogged fuel pipe.
Clean the pipe.
Replace the filter.

regulator.
Replace the fuel pressure regulator.


replace it.
Clean or replace the gasket.
Leakage of the vacuum hose.

replace it.
Overtheated
engine
Refer to Overheat in this page.
Malfunction of
fuel system
Abnormal spark plug.
Replace the spark plug.
Adjust the ignition timing


replace it.
Malfunction of
ignition system
Clogged or contaminated fuel filter

and fuel pipe.
Clean or replace the fuel filter and

the fuel pipe.
Others
Replace the gasket.
Excessive carbon deposit due to

abnormal combustion.
Remove the carbon.
Lack of coolant.
Refill coolant.
Malfunction of the thermostat.
Replace the thermostat.
Malfunction of the cooling fan.
Check or replace the cooling fan.
Poor water pump performance.
Replace the pump.
Clogged or leaky radiator.
Clean, repair or replace the

radiator.
Poor engine oil.
Replace engine oil with the specified one.
Blocking oil filter or strainer.
Clean or repair the oil filter or the

strainer.
Lack of engine oil.
Refill oil.
Poor oil pump performance.
Replace or repair the pump.
Leakage of oil
Repair.
Damaged cylinder head gasket.
Replace the gasket.
Malfunction of
ignition system
Malfunction of
cooling system
Malfunction of
lubrication
system
Other
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Correction
Decline of
compression
pressure
Others
Excessive
detonation
(According to the
opening range of
Malfunction of
metallic is made
with abnormal
explosion)
Probable Cause
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-13

Condition
Poor fuel consumption
Excessive
consumption of
engine oil
Refer to Page 1A-6.
Refer to Page 1A-6.
Malfunction of
fuel system
Leakage of the fuel tank or the fuel

pipe.
Repair or replace the fuel tank or

the fuel pipe
Malfunction of
ignition system
Abnormal spark plug

(Excessive carbon deposit,
inadequate gap, burnt electrode).
Replace the plug.

Connect the cable normally or

replace it.
Malfunction of
cooling system
Repair the thermostat.
Others
Improperly installed valve.
Repair or replace the valve.
Low pressure of tires.
Adjust the pressure of tires.
Loosened oil drain plug.
Tighten the plug.
Loosened oil pan bolt.
Tighten the bolt. Engine Oil
Loosened oil filter.
Tighten the filter.
Loosened oil pressure switch.
Tighten the switch.
Leakage of camshaft front oil seal.
Replace the seal.
Leakage of crankshaft front oil seal.
Replace the seal.
Leakage at the cylinder head cover

gasket.
Replace the gasket.
Damage of the cylinder head

gasket.
Replace the gasket.
Stuck piston ring.
Remove carbon and replace the

ring.
Worn piston or cylinder.
Replace the piston or the cylinder.
Worn piston ring or ring groove.
Replace the piston or ring.
Inadequate position of the piston

ring cutting part.
Adjust the position.
Abrasion or damage of the valve

system.
Replace the valve system.
Inadequate oil viscosity.
Replace with the specified one.
Loosening of the oil pressure

switch.
Tighten the switch.
Lack of engine oil.
Refill oil.
Blocking oil strainer.
Clean the strainer.
Lowered function of the oil pump.
Replace the pump.
Abrasion or damage of the oil pump

relief valve.
Replace the valve.
Leakage of
engine oil
Malfunction of
lubrication
system
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
Correction
Decline of
compression
pressure
Oil mixing in
combustion
chamber
Low oil
pressure
Probable Cause
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1A-14

Condition
Engine noise
Valve noise
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Correction
Inadequate valve clearance
Adjust the valve clearance.
Abrasion of valve stem or guide.
Replace the valve stem or the

guide.
Weak valve spring.
Replace the spring.
Piston, ring, cylinder noise
Abrasion of the piston, the ring or

the cylinder.
Boring the cylinder or replace the

piston, the ring or the cylinder.
Connecting rod
noise
Abrasion of the connecting rod

bearing.
Replace the bearing.
Loosened the connecting rod nut.
Tighten to the specified torque
Abrasion of the crankshaft bearing.
Abrasion of the crankshaft journal.
Grind or replace the crankshaft

journal.
Loosened bearing cap bolt.
Excessive clearance of the crankshaft thrust bearing.
Adjust or replace.
Low oil pressure.
Refer to Page 1A-13 in this

section.
Crankshaft noise
EFFECTIVE DATE
Probable Cause
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-15
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application
M162 Engine
M162.990
Engine model
Displacement
(CC)
3199
Cylinder (Bore x Stroke)
(mm)
89.9 x 84.0
MSE 3.63D
Fuel injection / Ignition system
10 : 1
Compression ratio
Number of cylinders
DOHC
Camshaft valve arrangement
Chain-Driven
Camshaft drive type

Max. output
(ps/rpm)
220 / 6000
Max. torque
(kgm/rpm)
31.6 / 3900
Firing order
1-5-3-6-2-4
Ignition type
Distributorless double ignition

BTDC 8
Ignition timing
Valve timing
Intake
Open/Close
ATDC 11 / ABDC 34
Exhaust
Open/Close
BBDC 31 / BTDC 14
Automatic control
Valve clearance adjustment

Idle speed
Fuel injection pressure
Oil capacity
Lubrication type
Oil filter type
Fuel
(rpm)
(kg/cm)
(liter)
700 50
3~4
9
Forced by gear pump
Full flow with paper filter
Unleaded gasoline
MSE: Engine Control Module

3.63D: 6 Cylinder Version
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
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1A-16
PERFORMANCE CURVE
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GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
1A-17
SPECIAL TOOLS AND EQUIPMENT

Name and Part Number
A9912 0012B (001 589 76 21 00)
Compression Pressure Tester
GENERAL INFORMATION
M162 GSL ENG SM - 2005.7
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1B-2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
ENGINE ASSEMBLY
1. Engine assembly
Tools Required
A9946 0012A (000 589 40 37 00)
Hose Clamp
W9936 0160A (112 589 00 72 00)
Oil Extractor
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ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-3
Removal & Installation Procedure

1. Disconnect the negative terminal of battery.
2. Remove the hood & front bumper.
3. Remove the under cover.
Installation Notice
Tightening torque
28 ~ 47 Nm
(21 ~ 35 lb-ft)
4. Disconnect the Hot Film Air Mass (HFM) sensor

connector.
5. Disconnect the HFM sensor from the air filter housing.
6. Remove the intake air duct mounting nuts.
Installation Notice
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
7. Remove the air cleaner cover. Remove the mounting bolts

and air cleaner housing and element assembly.
8. Remove the hood latch cable and remove the radiator

support upper member.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
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1B-4
9. Disconnect the each connector.
(Electric fans, AQS sensor, ambient temperature switch,
receiver drier)
10. Disconnect the each hose / A/C pipe.
11. Disconnect the hoses from the radiator and remove the
cooling fan shroud.
12. Remove the automatic transmission oil cooler line.

Installation Notice
Tightening torque
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25 ~ 35 Nm
(18 ~ 26 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-5
13. Remove the radiator assembly.
14. Remove the hydraulic pipe of power steering.

Installation Notice
Tightening torque
40 ~ 50 Nm
(30 ~ 37 lb-ft)
Completely drain the oil.
15. Discharge the refrigerant from A/C system, and

disconnect the discharge pipe and suction pipe from
the compressor. Refer to Section 7B, Manual Control
Heating, Ventilation, and Air Conditioning System.
Installation Notice
Tightening torque
20 ~ 30 Nm
(15 ~ 22 lb-ft)
16. Remove the fuel feed and return line.

Installation Notice
Tightening torque
21 ~ 25 Nm
(15 ~ 18 lb-ft)
Before removing the fuel lines, release the pressure in

the fuel system.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
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1B-6
17. Separate the vacuum hose for brake booster.
18. Separate the other vacuum hoses.
19. Separate the hose toward engine from canister purge

solenoid valve.
20. Disconnect the terminal from starter motor and remove

the starter motor.
21. Disconnect the engine main harness ground.
22. Disconnect the engine ground wire.
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ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-7
23. Disconnect the terminals from the alternator.
24. Disconnect engine main wiring connector.
25. Remove the service hole cover in the engine block.

26. Put the alignment mark for installation, and remove the
six mounting bolts for torque converter from drive plate
through the service hole by rotating the engine and
remove the torque converter.
Installation Notice
Tightening torque
42 Nm (31 lb-ft)
Screw the six bolts mounting the torque converter

through the service hole by using a mirror and
rotating the engine.
27. Remove the exhaust manifold and exhaust pipe.
Installation Notice
Tightening torque
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
30 Nm (22 lb-ft)
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1B-8
28. Remove the transmission mounting bolts and separate
the transmission from the engine.
Installation Notice
Tightening torque
54 ~ 68 Nm
(40 ~ 50 lb-ft)
29. Install a chain to the bracket of engine, by using a hoist

or crane.
30. Remove the engine mounting bracket nuts.
Installation Notice
Tightening torque
Upper: 70 Nm (52 lb-ft)

Lower: 38 Nm (28 lb-ft)
31. Carefully separate the engine assembly from the

vehicle.
32. Installation should follow the removal procedure in the
reverse order.
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ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-9
POLY V-BELT AND TENSIONING DEVICE

POLY V-BELT
Preceding Work: Removal of cooling fan
1. Poly V-belt
2. Belt tensioning pulley

1. Release the belt tension by turning the belt tensioning
pulley nut clockwise.
Installation Notice
Tightening torque
40.5 ~ 49.5 Nm
(29.9 ~ 36.5 lb-ft)
2. Remove the poly v-belt.

Notice
Check the belt for damage and tensioning pulley
bearing point for wear and replace them if necessary.
3. Install the belt by turning the nut of tensioning pulley
clockwise.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
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1B-10
Poly V-Belt Arrangement
5. Generator pulley
2. Crankshaft belt pulley
6. Idler
3. A/C compressor pulley
7. Power steering pump pulley
4. Cooling fan pulley
8. Cooling fan and water pump pulley
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ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-11
POLY V-BELT INSPECTION

Make marks on the belt with chalk.
Rotate the engine and check the belt for damage.
Notice
If one of the following types of damages is found,
replace the belt.
1. Rubber lumps in the base of rib.

2. Dirt or grit ingrained.
3. Pointed rib.
4. Belt cord visible in the base of rib.
5. Cord torn out at the side.

6. Outer cords frayed.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
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1B-12
7. Rib detached from the base of belt.
8. Splits across the rib.

9. Sections of rib torn out.
10. Splits across several ribs.
11. Splits across the back of the belt.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-13
TENSIONING DEVICE
Preceding Work: Removal of poly v-belt
1. Belt (L = 2245)
3. Water pump pulley
2. Bolt combi (M8 x 14, 3 pieces) + Washer
4. Nut
............................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-14

1. Remove the poly v-belt.
2. Remove the tensioning pulley by turning its mounting
nut counter clockwise as shown in figure.
Installation Notice
Tightening torque
40.5 ~ 49.5 Nm
(29.9 ~ 36.5 lb-ft)
3. Remove the bolts and remove the water pump pulley.

Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
4. Remove the mounting bolts (M8 x 30, 3 pieces) at the

tensioning device, and remove the tensioning device.
Installation Notice
Tightening torque
26 ~ 32 Nm (19 - 24 lb-ft)

reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-15
CRANK CASE AND CYLINDER HEAD

CRANKCASE VENTILATION SYSTEM
1. Crankcase
9. Air admission line
2. Air admission port in crankcase 10. Vent line
17. Air admission and vent connection

18. Air admission and vent connection
3. Oil drain port
11. Restriction hole (diameter = 2 mm) 19. Throttle valve
4. Filter
12. Intake manifold
5. Gasket
13. Intake air duct (cross pipe)
6. A/C bracket
A. Fresh air
7. Oil drain pipe
15. Oil separator
B. Blowby gas in partial load
8. Oil pan
16. Oil separator
C. Blowby gas in full load
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
20. Vent line
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-16
Operation at Idling and Mid-Load

It show that the throttle valve (19) is closed or very partially
opened and the vacuum pressure in intake manifold is high.
The blowby gas in the crankcase in partial load flows into
the intake manifold through the vent line (20) after passing
the air conditioner bracket (6) and the filter (4). The air
reentered into the intake manifold will be dilluted on the
flow through the restriction hole (11) in the vent line (10).
The circulated engine oil is separated at the air conditioner
bracket (6) and then returns into the oil pan through the
drain pipe (7).
The vacuum pressure generated at the crankcase sucks
fresh air from intake air line (13) through the air admission
and vent connection (17, 18).
The fresh air prevents engine oil from being contaminated
and the air admission and vent connection (17, 18) is
designed to control the rapid pressure changes in intake
air line (13).
Operation at Full-Load
The throttle valve (19) is fully opened.
All the blowby gases flow into the intake air duct (13) after
passing through the oil separator (15, 16) of the cylinder
head cover (14) when fully loaded. This dilluted air will be
supplied to the combustion chamber through the intake
manifold (12).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-17
ALTERNATOR
1. Nut (M8) ............ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
4. Bolt (M8 x 70, 1 piece)

............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
2. Bolt (M8 x 30, 3 pieces)

............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)

............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)

............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)

1. Remove the drive belt.
2. Remove the alternator.
3. Unscrew the alternator carrier bolts and remove the
carrier.
Installation Notice
Tightening torque
25 Nm (18 lb-ft)

reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-18
POWER STEERING PUMP AND A/C BRACKET

Preceding Work: Removal of cooling fan and shroud
1. Vent hose
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
3. Power steering pump
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
5. Washer
6. A/C compressor
7. Bolt (M8 x 40, 3 pieces, M8 x 95, 2 pieces)

............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
8. A/C bracket
9. Gasket .......................................................... Replace
10. Bracket
............................ 22.5 ~ 27.5 Nm (16.5 ~ 20.5 lb-ft)
12. Tensioning pulley
13. Nut ...................... 40.5 ~ 49.5 Nm (29.9 ~ 36.5 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-19

1. Remove the belt tensioning pulley.
Installation Notice
Tightening torque
40.5 ~ 49.5 Nm
(29.9 ~ 36.5 lb-ft)
Pull the tensioning pulley clockwise as shown in the

figure.
2. Disconnect the hydraulic pipe of the power steering pump

and drain the oil.
3. Unscrew the bolts and remove the steering pump.

Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
4. Remove the compressor after disconnecting the wiring

connector and refrigerant pipe of A/C compressor.
Notice
Discharge all the refrigerant before removing the
pipes.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-20
5. Disconnect the vent hose from the A/C bracket.
Installation Notice
20 ~ 30 Nm
Tightening torque
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(15 ~ 22 lb-ft)
6. Unscrew all the mounting bolts and remove the

A/C bracket and the gasket.
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
7. Clean the sealing surface.

8. Replace the gasket with new one.
reverse order.
10. Check the oil leakage by operating the engine after
installation.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-21
ENGINE MOUNT
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-22
Removal and Installation Procedure

1. Unscrew the upper engine mounting nut.
Installation Notice
Tightening torque
70 Nm (52 lb-ft)
2. Unscrew the lower engine mounting nut.

Installation Notice
Tightening torque
38 Nm (28 lb-ft)
3. Remove the hydraulic engine mounting insulator.

Notice
If the insulator is spotted with oil, replace the
hydraulic insulator asseambly.
reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-23
CYLINDER HEAD COVER
1. Ignition cable dust cover
2. Bolt (M6 x 65, 8 pieces) .... 9 ~ 11 Nm (80 ~ 97 lb-in)
7. Gasket .......................................................... Replace
3. Bolt (M6 x 50, 4 pieces) .... 9 ~ 11 Nm (80 ~ 97 lb-in)
8. Spart plug hole seal ..................................... Replace
4. Spacer sleeve
9. Camshaft seal .............................................. Replace
5. Thrust piece
Composition of The Cylinder Head

Cover Bolts
A. M6 x 50, 4 Pieces - Bolts + Washers
B. M6 x 65, 8 Pieces - Bolts + Washers
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-24

1. Remove the intake air duct.
Installation Notice
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
2. Remove the spark plug cover.

Installation Notice
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
Unscrew the seven (M6 x 60) bolts and remove the spark
plug cover.
3. Remove the spark plug connector and ignition cable.
4. Unscrew all the bolts (2, 3) and remove the head cover
and the gasket.
Installation Notice
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
Replace the gasket with a new one if necessary.

reverse order.
6. Check for oil leaks by operating the engine.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-25
CYLINDER HEAD FRONT COVER

Preceding Work: Removal of cylinder head cover
Removal of coolant connection fitting
1. Camshaft position sensor
............................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
2. Camshaft actuator
3. Upper guide rail
6. Front cover
7. Rubber gasket .............................................. Replace
............................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)

.......................................... 9 ~ 11 Nm (80 ~ 97 lb-in)

1. Remove the camshaft actuator.
Installation Notice
Tightening torque
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
9 ~ 11 Nm
(80 ~ 97 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-26
2. Remove the cylinder head front cover (6).
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Apply the sealant at the mating surface of the cylinder

head and the front cover.
3. Remove the upper guide rail pin and the guide rail (3).
Notice
Install it while the chain tensioner is loose.
4. Remove the gasket (arrow).
Notice
Replace the gasket with new one and apply the
sealant.
reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-27
CYLINDER HEAD
Removal of cylinder head front cover
Removal of upper intake manifold
1. Cylinder head bolt (14 pieces)

......................... 1st step: 55 Nm (141 lb-ft)
4. Exhaust camshaft sprocket

5. Cylinder head
2nd step: 90
6. Gasket .......................................................... Replace
3rd step: 90
7. Dowel sleeve
2. Washers (14 pieces)

3. Flange bolts (3 pieces)
......................... 1st step: 18 ~ 22 Nm (13 ~ 16 lb-ft)
2nd step: 90 5
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-28
Tools Required
A9913 0061B (116 589 01 34 00)
Threaded Pin
A9913 0080B (116 589 20 33 00)
Sliding Hammer
A9912 0080B (617 589 00 10 00)
Allen Wrench Socket

1. Rotate the crankshaft so that the piston of number 1
cylinder is at TDC.
Notice
Rotate the crankshaft in the normal engine direction.
2. Put the alignment marks (arrows) on the timing chain
and camshaft sprocket.
3. Drain the coolant from the crankcase.
4. Remove the three flange bolts in the exhaust camshaft

sprocket.
Installation Notice
1st step: 18 ~ 22 Nm
Tightening torque
(13 ~ 16 lb-ft)
2nd step: 90 5
Do not reuse the removed bolts.
5. Separate the chain from the camshaft sprockrt.

Notice
Be careful not to drop the chain into the timing case.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-29
6. Remove the guide rail fixing pin from the cylinder head
using the threaded pin A9913 0061B (116 589 01 34 00)
(1) and sliding hammer A9913 0080B (116 589 20 33 00)
(2).
7. Remove the cylinder head bolts in numerical order using

allen wrench socket A9912 0080B (617 589 00 10 00).
Installation Notice
1st step: 55 Nm (41 lb-ft)
Tightening torque
2nd step: 90
3rd step: 90
8. Check the length of the cylinder head bolt.

Installation Notice
Length (L)
New 160 0.8 mm

Max. 162 0.7 mm
Replace the bolt if the measured length exceed the

max. length.
Apply the oil to the thread surface of bolt.
9. Carefully remove the cylinder head and check the mating

surface.
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-30
OIL PAN
1. Gasket ...................................................... Replace

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. Drain plug ...... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
7. Bolt (M10) ................................... 40 Nm (30 lb-ft)
8. Oil pan
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-31

1. Remove the drain plug and drain the oil completely.
2. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then apply
the sealant.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine.
M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
Others
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
M6 X 22, 6 pieces
M6 X 20, 28 pieces
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-30
OIL PAN
1. Gasket ...................................................... Replace

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. Drain plug ...... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
7. Bolt (M10) ................................... 40 Nm (30 lb-ft)
8. Oil pan
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-31

1. Remove the drain plug and drain the oil completely.
2. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
3. Clean the inside of oil pan and sealing surface, then apply
the sealant.
5. Install the oil pan with gasket, and tighten each bolt in
specified torque.
6. Check for oil leaks while running the engine.
M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
Others
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
M6 X 22, 6 pieces
M6 X 20, 28 pieces
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-32
TIMING GEAR CASE COVER

Preceding Work: Removal of cylinder head front cover
Removal of generator bracket
Removal of tensioning device
Removal of belt pulley and vibration damper

....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)

....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
2. A/C bracket
6. Seal
7. Timing gear case cover
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)

....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
8. Roll pin
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-33

1. Put the alignment marks (arrows) on the timing chain
and camshaft sprocket.
2. Unscrew the A/C bracket bolts (1) and remove the
bracket.
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
3. Remove the cooling fan and the viscous clutch. Unscrew

the three bolts from the cooling fan bracket and remove
the bracket.
Installation Notice
22.5 ~ 27.5 Nm
Tightening torque
(16.6 ~ 20.3 lb-ft)
4. Remove the timing gear case cover after unscrewing the

bolts (3) and (4) from the timing gear case cover and the
bolt (9) from the oil pan.
Notice
Be careful not to damage the oil pan gasket.
Installation Notice
Bolt (3, 4)
Tightening torque
Bolt (9)
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 Ib-ft)
9 ~ 11 Nm
(80 ~ 97 Ib-ft)
Apply the sealant after cleaning the timing gear case

cover surface.
Be careful not to stain the oil chamber of chain
tensioner with the sealant.
reverse order.
6. Warm up the engine and check for oil leaks.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-34
CRANKSHAFT SEALING REAR COVER

Preceding Work: Removal of the automatic transmission drive plate

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
2. Radial shaft seal
3. Rear cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4. Sleeve
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
6. Washer
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-35
Tools Required
W9911 0020B (601 589 03 43 00) Crankshaft Rear Seal Installer

1. Unscrew the bolts (1) and (5) and remove the closing
cover by pulling the rear cover lug (arrows).
Notice
Be careful not to damage the oil pan gasket.
2. Clean the sealing surface of the crankcase and the rear

sealing cover.
3. Check the radial shaft seal and replace it if necessary.
4. Apply the Loctite 573 to the rear cover sealing surface.
5. Apply the engine oil to the dust lip of the radial shaft
seal.
Notice
Do not use the grease.
6. Install the crankshaft rear radial seal and the crankshaft

sealing rear cover, using crankshaft rear seal installer
W9911 0020B (601 589 03 43 00).
7. Install the crankshaft sealing rear cover mounting bolts

and remove the crankshaft rear seal installer W9911
0020B (601 589 03 43 00).
Installation Notice
Tightening torque
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
9 ~ 11 Nm
(80 ~ 97 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-36
CRANKSHAFT ASSEMBLY
BELT PULLEY AND VIBRATION DAMPER
Preceding Work: Removal of cooling fan and viscous clutch
Removal of fan shroud
Removal of drive belt
1. Center bolt (M18 x 50)

............. 1st step: 80 ~ 220 Nm (133 ~ 162 lb-ft)
2nd step: 90 + 10
2. Vibration damper disk
4. Vibration damper assembly

5. Woodruff key
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
........................... 7.7 ~ 9.5 Nm (68.1 ~ 84.1 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-37
Components
7. Crankshaft sprocket (camshaft driven)
2. Vibration damper disk
8. Crankshaft sprocket (oil pump driven)
3. Vibration damper and pulley assembly
9. Crankshaft
4. Woodruff key
10. Oil pan
5. Crankshaft front seal
11. Oil pan gasket
12. Oil pan mounting bolt (M6 x 22)
Service Data Standard

Permissble Deviation of The Vibration Damper
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
Radial Runout
0.6 mm
Axial Runout
0.6 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-38
Tools Required
A9910 0150B (602 589 00 40 00)
Engine Lock

1. Adjust the piston of number 1 cylinder to the TDC.
2. Remove the start motor and install the engine lock A9910
0150B (602 589 00 40 00) to the flywheel ring gear.
3. Remove the vibration damper center bolt.
Installation Notice
1st step: 180 ~ 220 Nm
Tightening torque
(133 ~ 162 lb-ft)

2nd step: 90 + 10
4. Remove the vibration damper assembly using the puller.

reverse order.
Notice
If possible, dont separate the vibration damper and
the pulley.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-39
CRANKSHAFT FRONT RADIAL SEAL

Preceding Work: Removal of belt pulley and vibration damper

.......... 1st step: 180 ~ 220 Nm (133 ~ 162 lb-ft)
2nd step: 90+10
3. Sleeve (special tool)

5. Key
2. Center bolt washer
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-40
Tools Required
A9911 0060B (601 589 03 14 00)
Crankshaft Front Seal Installer
Replacement Procedure
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal
mounting hole and the crankshaft.
2. Coat the radial sealing lip with engine oil.
3. Using the crankshaft front seal installer A9911 0060B
(601 589 03 14 00), assemble the radial seal.
4. Align the sleeve groove and the woodruff key and tighten
the center bolt until the center bolt and the damper disk
stop in the movement.
Installation Notice
1st step: 180 ~ 220 Nm
Tightening torque
(133 ~ 162 lb-ft)

2nd step: 90 + 10
5. Remove the crankshaft front seal installer A9911 0060B

(601 589 03 14 00), and install the belt pulley and the
vibration damper.
6. Check for leaks while operating the engine.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-41
CRANKSHAFT REAR RADIAL SEAL

Preceding Work: Removal of flywheel or drive plate
1. Special tool
3. Crankshaft rear seal
2. Special tool
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-42
Tools Required
W9911 0020B (601 589 03 43 00)
Crankshaft Rear Seal Installer
Replacement Proceudre
1. Remove the radial seal with a screw driver.
Notice
Use a clean cloth not to damage the radial seal
mounting hole and the crankshaft.
2. Install the crankshaft rear seal installer W9911 0020B
(601 589 03 43 00) (2) to the crankshaft.
3. Apply the engine oil on the crankshaft rear seal installer
W9911 0020B (601 589 03 43 00) (2).
Notice
Do not use the grease.
4. Install the radial seal on the inner parts assembler.
5. Press in the crankshaft rear seal installer W9911 0020B
(601 589 03 43 00) (1) until the radial seal is stopped.
6. Check for leaks while operating the engine.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-43
CRANKSHAFT
Preceding Work: Removal of engine assembly
Removal of timing gear case cover
Removal of cylinder head
Removal of crankshaft sealing rear cover
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1. Crankshaft bearing cap bolt (M8 x 55, 14 pieces)

................... 1st step: 50 ~ 60 Nm (37 ~ 44 lb-ft)
2nd step: 90 + 5
3. Crankshaft lower main bearing

4. Crankshaft lower thrust bearing
5. Crankshaft
2. Crankshaft bearing cap
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-44
Arrangement of the Thrust Bearing and the Main Bearing
1. Upper main bearing
A. Crankcase side
2. Upper thrust bearing
B. Bearing cap side (oil pan side)
3. Crankshaft
C. Axial fit bearing (number 5 bearing point)
4. Lower main bearing
D. Radial bearing
5. Lower thrust bearing
1 - 12
j1 - j7
Weight Balance/Color Marking Point

Journal Main Bearing #1 - #7
Color Dot Marking
The color dot marking are put on the 1 , 2 , 4 , 6 , 8 , 10 ,

12 and it indicates the diameter of crankshaft journal by
color as below.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-45
Color Dot Marking Crankshaft Journal Diameter (mm)
Blue
57.960 ~ 57.965
Yellow
57.955 ~ 57.960
Red
57.950 ~ 57.955
White
57.945 ~ 57.950
Violet
57.940 ~ 57.945
Selection of Crankshaft Main Bearing

1. Crankcase Side
There are seven punching marks on the mating surface
to oil pan. This mark is correspondent to the bearing
distinguished by color. Select the relevant bearing
according to the punching mark when repaired.
Punching Mark
Bearing Color Selected

Blue
Yellow
Red
2. Crankshaft Bearing Cap Side

Select the crankshaft main bearing according to the
marking letter on the crankshaft main journal when
repaired.
Marking Letter
Bearing Color Selected
Blue
Yellow
Red
White
Violet
Service Data
Unit: mm
Crankshaft
Crankshaft
Connecting Rod
Crankshaft Standard
Thrust Washer
Bearing Journal
Journal Width Bearing Journal
and Repair Size
Thickness
Diameter
at fit bearing
Diameter
Standard size
57.950 ~ 57.965
1st repair size
57.700 ~ 57.715
2nd repair size
57.450 ~ 57.465
3rd repair size
57.200 ~ 57.215
4th repair size
56.950 ~ 56.965
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
2.15 or 2.20
2.25 or
2.35 or
2.40
24.50 ~ 24.533
47.94 ~ 47.96
Connecting Rod
Bearing Jourmal
Width
27.958 ~ 28.042
47.75
-
47.50
47.25
47.00
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-46

1. Unscrew the connecting rod bearing cap bolt and remove
the bearing cap.
Installation Notice
1st step: 40 + 5 Nm
Tightening torque
(30 + 3.7 lb-ft)

2nd step: 90 + 10
Make sure that the upper and lower bearing shells do

not change each other.
Coat the bearing shell with engine oil.
Install the bearing cap according to the consecutive
number.
2. Unscrew the crankshaft bearing cap bolts and separate

the upper and lower bearing shells and thrust washers.
Installation Notice
Tightening torque
(37 ~ 44 lb-ft)
2nd step: 90
Part No. : 601 030 00 62 2.15 mm
Remove the bearing cap from front (pulley side) to rear.
Make sure that the upper and lower bearing shells do

not change each other and coat with engine oil.
The oil grooves (arrows) in the thrust washers must face

outward and insert the thrust bearing into the bearing
cap.
There are five kinds of thrust washers by thickness.

Select the proper washer when repaired.
Part No. : 601 030 01 62 2.20 mm

Part No. : 601 030 02 62 2.25 mm
Part No. : 601 030 03 62 2.30 mm
Part No. : 601 030 04 62 2.40 mm
3. Remove the crankshaft.

reverse order.
5. After completion of the installation, check for the rotating
condition of the crankshaft.
Notice
Make sure the crankshaft bearing cap properly
seated in place in the crankcase side. When perfectly
installed, the projected part (arrow) locates in the
left side (intake manifold side).
Assemble so that the projected part of the cap and

crankcase face the same direction.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-47
Inspection
1. If the length L of the crankshaft bearing cap bolt exceeds
63.8 mm, replace it.
2. Make sure the crankshaft bearing cap is properly seated

on the cylinder block (arrows).
3. Measure and record the inner diameter of the crankshaft

bearing.
Notice
Measure at 2 points (1, 2).
Measure A,Band C as shown. If average value

of B and Cis less than value A, then the average
value of B and C is actual average value. If average
value of B and C is more than value A, then the
value A is actual average value.
4. Measure and record the diameter of the crankshaft

bearing journal.
Notice
Record the mean value when measured at 3 points
(A, B, C).
Measure the inner diameter of bearing and the

diameter of journal and if it is out of the standard
data, replace the bearing shell.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-48

(Crankshaft Main Bearing Gap)
Item
Measuring Position
Gap (mm)
Static condition: 0.015 ~ 0.039
Main Bearing Journal
Radial
(NO. 1, 5, 7)
Dynamic condition: 0.031 ~ 0.051

(Consider the expansion 0.011 ~ 0.016)
Axial
0.010 ~ 0.254
Static condition: 0.011 ~ 0.039
Main Bearing Journal
Radial
(NO. 3, 4, 6)
Dynamic condition: 0.031 ~ 0.051

(Consider the expansion 0.015 ~ 0.022)
Axial
0.010 ~ 0.254
(Connecting Rod Bearing Gap)

Item
Measuring Position
Gap (mm)
Connecting Rod Bearing
Radial
0.030 ~ 0.050
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-49
CONNECTING ROD
Preceding Work: Removal of piston
1. Connecting rod bushing
5. Fit sleeve
2. Oil gallery
6. Upper connecting rod bearing
3. Balance weight
7. Lower connecting rod bearing
4. Connecting rod bolt (M9 x 52, 12 pieces)
8. Bearing shell lug
...................... 1st step 40 + 5 Nm (30 + 3.7 lb-ft)
9. Marking [Indication ( ) or numbers]
2nd step 90 + 10

Distance (L) from the connecting rod bearing bore center to the bushing bore center
145 0.05 mm
Width of the connecting rod (B) at bearing bore
21.940 ~ 22.000 mm
Width of the connecting rod (b) at bushing bore
21.940 ~ 22.000 mm
Basic bore at the bearing shell (D1)
51.600 ~ 51.614 mm
Basic bore at the bushing (d1)
24.500 ~ 24.571 mm
Bushing inner diameter (d)
22.007 ~ 22.013 mm
Clearance between the piston pin and the bushing
0.007 ~ 0.018 mm
Peak-to-valley height of connecting rod bushing on inside
0.005 mm
Permissible twist of connecting rod bearing bore to connecting rod bushing bore
0.15 mm
Permissible deviation of axial paralleism of connecting rod bearing bore to connecting rod
0.07 mm
bushing core
Permissible deviation of connecting rod bearing bore from concentricity
0.01 mm
Permissible difference of each connecting rod in weight

ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
0.4 g
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-50
Inspection
1. Measure the basic bore of the connecting rod bearing.
Notice
If the basic bore exceeds the value of 51.614 mm,
replace the bearing or check the connecting rod.
2. Check connecting rod bolts.

Length when new (L)
51.7 ~ 52 mm
Max. Length (L)
52.9 mm
Tightening torque
1st step: 40 + 5 Nm
(30 + 3.7 lb-ft)
2nd step: 90 + 10
Notice
If the length exceeds max. length, replace it.
3. Check the assembly mark (indication//or number: arrow)

of the connecting rods and the bearing cap when
installing.
Notice
Make sure it doesnt exceed over 4g with other
connecting rods when replacing the connecting
rods.
Check if the connecting rod and the bearing cap

are accurately seated on the groove when replacing
the bearing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-51
PISTON
Preceding Work: Removal of engine
Removal of cylinder head
Removal of oil pan
Removal of oil pump
Removal of baffle plate
1. Connecting rod bearing cap
4. Piston
2. Connecting rod
5. Snap ring
3. Connecting rod bearing cap bolt
6. Piston pin
(M9 x 52, 12 pieces)

...................... 1st step: 40 + 5 Nm (30 + 3.7 lb-ft)
2nd step: 90 + 10
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-54
PISTON RING
Preceding Work: Removal of piston
1. Piston compression ring
4. Coil spring and control ring
2. Piston compression ring
5. Hook spring
3. Piston oil ring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-55
1. Measure the piston rings gap.
Groove 1 0.20 ~ 0.40 mm
End Gap of the
Piston Ring
Gap between the
Piston and the
Piston Ring
Groove 2 0.20 ~ 0.40 mm

Groove 3 0.20 ~ 0.45 mm
Groove 1 0.015 ~ 0.050 mm
Groove 2 0.020 ~ 0.040 mm
Groove 3 0.010 ~ 0.045 mm
Notice
If out of specification, replace the piston ring.
2. Remove the piston ring with a pliers.
3. For installation, position the piston ring to be the TOP

mark on the piston ring upward and arrange the piston
ring ends to be 120 apart.
4. Adjust the hook spring joint in the oil ring 180 away
from the ring end.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-56
FLYWHEEL/DRIVEN PLATE
Preceding Work: Removal of manual or automatic transmission
3. Driven plate (A/T)
1. Flywheel mounting bolt (M10 x 22, 8 pieces)
4. Dowel pin
..................... 1st step: 45 + 5 Nm (33 + 3.7 lb-ft)

2nd step: 90 + 10
2. Plate
Service Data Standard (Stretch Bolt)

Nominal size
M x 1.5
Stretch side diameter
When new
8.5 ~ 0.2 mm
Min. diameter
8.0 mm
When new
21.8 ~ 22.2 mm
Bolt length
Tightening torque
1st step: 45 + 5 Nm (33 + 3.7 lb-ft),

2nd step: 90 + 10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-57

1. Unscrew the driven plate mounting bolt.
Installation Notice
1st step: 40 + 5 Nm
Tightening torque
(30 + 3.7 lb-ft)

2nd step: 90 + 10
Replace the bolt when the stretch side diameter (d)

of the driven plate mounting bolt is less than 8.0 mm.
For the stretch bolt tightening, keep the socket
wrench and Tommy-bar to be 90 and tighten as
specified.
2. Remove the driven plate (3), and plate (2) for automatic
transmission vehicle.
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-58
Sectional View
1. Oil pan
8. Washer
2. Cover
9. Bolt
10. Front drive plate
4. Flywheel mounting bolt
11. Rear drive plate
5. Crankshaft
12. Rivet
6. Dowel pin
13. Segment
7. Washer (thickness = 3.5 mm)
14. Ring gear
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-64
CAMSHAFT SPROCKET BOLT

Intake Flange Shaft Bolt
Installation Notice
Tightening Torque
(13 ~ 16 lb-ft)
2nd step: 90 5
The sprocket bolts are designed to be used only once, so

always replace with new one.
C. M7 x 13 Collar Bolt Torx-T30
e. 6.8 mm
16. Flange shaft
18. Control piston
22. Intake camshaft
Exhaust Camshaft Sprocket Bolt

Installation Notice
Tightening torque
(13 ~ 16 lb-ft)
2nd step: 90 5
The sprocket bolts are designed to be used only once, so

always replace with new one.
E. M7 x 13 Collar Bolt Torx-T30

e. 6.8 mm
13a. Camshaft sprocket
22a. Exhaust camshaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-65
CAMSHAFT
Removal of coolant connection fitting
1. Chain tensioner assembly

.................................... 72 ~ 88 Nm (53 ~ 65 lb-ft)
4. Cylinder head front cover

5. Intake camshaft sprocket
6. Chain
3. Upper guide rail
7. Wrench
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-66
Tools Required
A9917 0012B (DW 110-120)
Holding Pin
Removal Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30.
2. Remove the Alternator.
3. Remove the chain tensioner. Refer to Chain Tensioner
in this section.
4. Remove the cylinder head front cover and the upper guide
rail.
5. Put the alignment marks (arrows) on the camshaft

sprocket (2, 5) and the timing chain (6).
6. Unscrew the exhaust camshaft sprocket bolt and remove

the sprocket.
7. Separate the chain from the intake camshaft sprocket
and put the chain not to be dropped into timing case.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-67
8. Unscrew the intake side bolts (8, 11, 13, 14) and the
exhaust side bolts (1, 4, 6, 7).
9. Loosen the remaining bolts and unscrew the intake and
exhaust side camshaft bearing cap bolts.
Notice
Number the camshaft bearing cap bolts when
removing them, so that they dont get mixed up.
10. Remove the intake and exhaust camshafts.
Installation Procedure
1. Turn the crankshaft and position the No. 1 cylinder piston
at BTDC 30.
Notice
Turn the crankshaft in the direction of engine rotation.
2. Install the exhaust camshaft bearing caps (2, 3, 5) and

the intake camshaft bearing caps (9, 10, 12). Tighten
the bolts with specified torque and install the remaining
bearing caps.
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Install the bearing caps according to the numbers on the

bearing caps.
3. Turn the camshaft using the wrench so that the intake

camshaft adjustment hole lines up with the cylinder head
upper side (3 oclock direction at the intake, 9 oclock
direction at the exhaust).
Notice
Turn the crankshaft and adjust it to OT so that No. 1
cylinders piston would be at TDC.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-68
4. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin A9917 0012B
(DW 110-120) into the holes.
5. Turn the intake camshaft adjuster to the direction of

camshaft rotation by hard until it stops and then install
the chain.
Notice
Make sure that the camshaft sprocket and timing
chain are aligned with marks.
Intake camshaft adjuster should be in retarded
position.
6. Install the chain on the exhaust sprocket and tighten the

sprocket bolts.
Installation Notice
Tightening torque
(13 ~ 16 lb-ft)
2nd step: 90 5
Make sure that the camshaft sprocket and timing

chain are aligned with marks.
Replace the sprocket bolt with new one.
7. Install the chain tensioner screw plug (1) and chain

tensioner assembly (2) and tighten it as specified.
Installation Notice
(1) : 40 Nm (30 lb-ft)
Tightening torque
(2) : 72 ~ 88 Nm
(53 ~ 65 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-69
8. Rotate the crankshaft 2 revolutions and check followings:
- TDC of no. 1 cylinder: OT
- Alignment between camshaft adjustment hole and
cylinder head surface.
- Alignments between timing chain and sprocket
marks.
Notice
Turn the crankshaft in the direction of engine
rotation.
Read just if not aligned.
9. Install the upper guide rail and cylinder head front cover.
10. Install the Alternator.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-70
CAMSHAFT TIMING POSITION

1. Chain tensioner assembly
4. Cylinder head front cover
5. Wrench
3. Upper guide rail
6. Holding pin A9917 0012B (DW 110-120)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-71
Tools Required
A9917 0012B (DW 110-120)
Holding Pin
Inspection
1. Position the No.1 cylinder piston to TDC (OT) by turning
the crankshaft.
Notice
When the OT mark on vibration damper is aligned
with timing gear case cover, the intake and exhaust
cam of cylinder will make the slope to the center and
will face up. In this way, the adjustment hole of the
intake and exhaust camshaft will match in line with
the cylinder head upper end, at 3 oclock, and 9
oclock direction each other.
2. Check the timing as below procedure;
- Check if the camshaft adjustment hole is positioned
to 3 oclock direction at the intake side and to 9
oclock direction at the exhaust side, respectively
and align with the cylinder head mating surface.
- At this condition, check if the OT mark on vibration
damper aligns with the marker on the timing gear
case.
Adjustment Procedure
1. Position the No.1 cylinder to BTDC 30.
2. Remove the chain tensioner.
3. Remove the exhaust camshaft sprocket.
4. Align the intake and exhaust camshaft flange hole with
the cylinder head upper surface.
Intake Side: 3 oclock direction
Exhaust Side: 9 oclock direction
5. Align the holes on intake and exhaust camshaft to the
hole on cylinder head. Insert the holding pin A9917 0012B
(DW 110-120) into the hole.
6. Secure the intake and exhaust camshaft.
7. Position the piston of No.1 cylinder at TDC (OT) by
turning the crankshaft.
8. Turn the camshaft adjuster of the intake camshaft to the
left as much as possible (cam adjuster retarded
position).
9. Install the chain to the intake camshaft sprocket.
Notice
Timing chain must be placed on the guide rail in
gear case cover.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-72
10. Install the chain to the exhaust camshaft sprocket and
install it to the camshaft.
Installation Notice
Tightening torque
(13 ~ 16 lb-ft)
2nd step: 90 5
The sprocket bolt is designed to be used only once, so

replace with new one.
11. Install the chain tensioner.
Installation Notice
Tightening torque
Screw plug
40 Nm (30 lb-ft)
Tensioner
assembly
72 ~ 88 Nm
(53 ~ 65 lb-ft)
12. Check the camshaft timing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-73
VALVE SPRING
Preceding Work: Removal of camshaft
Removal of spark plug
1. Valve cotter
6. Connecting hose .... A9911 0012B (DW 110-090)
2. Upper retainer
7. Thrust piece ........... A9917 0121B (111 589 25 63 00)
3. Valve spring ............. Check, replace if necessary
8. Lever pusher ........... A9917 0111B (111 589 18 61 00)
4. Valve stem seal
9. Supporting bar ........ A9917 0101B (111 589 01 59 00)
5. Lower retainer
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-74
Tools Required
A9917 0101B (111 589 01 59 00)
Supporting Bar
A9917 0111B (111 589 18 61 00)
Lever Pusher
A9917 0121B (111 589 25 63 00)
Thrust Piece
A9910 0150B (602 589 00 40 00)
Engine Lock
A9911 0012B (DW 110-090)
Connecting Hose

1. Place the supporting bar A9917 0101B (111 589 01 59
00) (12) at the camshaft bearing cap and tighten them
with the bearing cap bolt.
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
2. Turn the crankshaft to position the each cylinder piston

at TDC.
Mark on The Vibration Damper
Cylinder
OT
1, 6
120
2, 5
240
3, 4
Notice
Remove the valve spring only at TDC.
Always rotate the crankshaft by holding the chain
to prevent from timing chain damage and tangling,
and for smooth rotation.
3. Remove the valve tappet (1) using the valve tappet remover.
4. Install the connecting hose A9911 0012B (DW 110-090)
to the spark plug hole.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-75
5. Install the engine lock to the ring gear to prevent the
crankshaft from rotating.
6. Blow up with compressed air.
7. Install the lever pusher A9917 0111B (111 589 18 61 00)

(8) and the thrust piece 111 589 25 63 00 (7).
8. Mount the thrust piece A9917 0121B (111 589 25 03 00)
(7) vertically to the valve spring retainer (2).
9. Press the valve spring (3) by using the lever pusher A9917
0111B (111 589 18 61 00) (8).
10. Remove the valve cotter (1) using the pincette.
11. Remove the upper retainer (2) and the valve spring (3).
12. Remove the valve stem seal (4).

Notice
Check the valve stem seal for damage and replace if
necessary.
13. Remove the lower retainer (5).
Notice
Check the retainer for damages and replace with a
new one if necessary.
reverse order.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-76
Test (Upper and Lower Valve

Tappet and Valve Cotter)
Upper Valve Spring Retainer
Size (mm)
(d)
8.5
(D)
12.3
(a)
0.8 ~ 1.0
(B)
9.0
(H)
9.2 ~ 9.8
Lower Valve Spring Retainer

Thickness (mm)
Valve Cotter
Size (mm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-77
VALVE STEM SEAL

Preceding Work: Removal of valve spring
1. Drift A9917 0171B (119 589 00 43 00)
3. Protective sleeve
2. Valve stem seal
Tools Required
A9917 0171B (119 589 00 43 00)
Drift
1. Remove the valve stem seal (2) using the pliers.
Notice
Check the valve stem seal for damage and replace if
necessary.
2. Coat the valve stem seal with oil and assemble it with
the protective sleeve.
3. Insert the valve stem seal by pressing it with the drift
A9917 0171B (119 589 00 43 00).
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-78
CHAIN TENSIONER
1. Screw plug .................................. 40 Nm (30 lb-ft)
6. Thrust pin
2. Seal
7. Chain tensioner housing
3. Filler pin
4. Compression spring
.................................... 72 ~ 88 Nm (53 ~ 65 lb-ft)

8. Seal
5. Snap ring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-79
Removal Procedure
1. Position the No.1 cylinder to TDC (OT).
Notice
Remove the oil filler cap at adjustment position, and
check whether the intake camshaft cams lobe (arrow)
stays in the upper side.
2. Cover the generator with a clean cloth.
3. Release the tension by unscrewing the screw plug once.
Notice
In case that the tension is reduced by unscrewing the
screw plug, reinstall after completely removing the
chain tensioner. If the chain tensioner is tightened
again without completely reducing its tension, then
the detent spring doesnt return to the original
position and the tension gets exceeded.
4. Carefully unscrew the screw plug (1), and remove the

seal (2).
Notice
For the removal of screw plug, be careful that it
can be jumped out due to the force of compression
spring.
Remove the screw plug only when the seal and
compression spring are damaged.
5. Carefully remove the filler pin (3), compression spring

(4), snap ring (5), and the thrust pin (6).
6. Remove the chain tensioner housing (7) and the seal (8).
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-80
Installation Procedure
1. Connect the thrust pin (6) and the snap ring (5) to the
chain tensioner housing (7).
Notice
When connecting the thrust pin, push in the thrust
pin far enough so that it doesnt protrude at the chain
tensioner housing.
2. Install the chain tensioner housing (7), thrust pin (6), snap
ring (5), and the seal (8).
Installation Notice
Tightening torque
72 ~ 88 Nm
(53 ~ 65 lb-ft)
3. Insert the compression spring (4) with the filler pin (3)
into chain tensioner housing.
4. Lightly apply the grease to the seal (2) and install the
screw plug (1).
Installation Notice
Specified value
40 Nm (30 lb-ft)
5. Check for leaks by operating the engine.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-81
Sectional View
1. Screw plug
13. Chain tensioner housing
2. Ball (nonreturn valve)
14. Seal
4. Ball guide
16. Cylinder head
5. Seal (aluminum)
17. Bolt/Washer
6. Filler pin
18. Tensioning rail
19. Cylinder head gasket
8. Snap ring
20. Timing chain
9. Thrust pin
21. Tensioning rail base (sliding surface)
10. Ball (nonreturn valve)

A. Oil supply hole
12. Thrust piece
B. Chain tensioner oil storage hole
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-82
TIMING CHAIN
Removal of spark plug
1. Pin
5. Link
2. New timing chain
6. Center plate
3. Timing chain (used)
7. Outer plate
4. Wedge
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-83
Tools Required
A9913 0010B (000 589 58 43 00)
Chain Assembly
A9917 0012B (DW 110-120)
Holding Pin
1. Position the No.1 cylinder to TDC (OT).
2. Insert the holding pin A9917 0012B (DW 110-120) to the

intake and exhaust camshaft flange not to rotate
camshaft.
4. Mount the wedges to both sides of the camshaft sprocket

as shown in the figure.
5. Cover the chain housing with a clean cloth, and grind off
the timing chain pin from the intake camshaft sprocket
with the grinder.
FUEL SYSTEM
M162 GSLENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-84
6. Remove the outer plate (7) with the screw driver and
remove the link.
7. Connect the new timing chain (2) to the used timing chain
(3) with the link (5), center plate (6, thickness 1.6 mm),
and the outer plate (7).
8. Rotate the crankshaft in the direction if engine revolution
by pressing the new timing chain against the exhaust
camshaft sprocket to prevent it to be tangled.
Notice
Be sure to remove the wedge before cranking the
engine.
9. Take out the used timing chain out from the chain housing.
10. Connect both separators of the new timing chain with
the link (5) and the center plate (6).
11. Install the jaw (a) and the thrust piece (b) to the assembly
tool as shown in the figures.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-85
12. Place the outer plate (7, thickness 1.2 mm) inside the
thrust piece (b).
13. Install the chain assembly A9913 0010B (000 589 58 43

00) above the link and tighten the spindle (c) until a block
is felt.
14. Place the chain assembly A9913 0010B (000 589 58 43
00).
15. Replace the thrust piece (b) as shown in the figure.
16. Install the chain assembly A9913 0010B (000 589 58 43

00) to the link pin and tighten the spindle (c).
Installation Notice
Tightening torque
FUEL SYSTEM
M162 GSLENG SM - 2005.7
30 Nm (22 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-86
17. Rivet the link pin.
Check the condition and it again if necessary.
Installation Notice
Tightening torque
Screw plug
40 Nm (30 lb-ft)
Tensioner
assembly
72 ~ 88 Nm
(53 ~ 65 lb-ft)
19. Check the camshaft timing position.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
M162 GSL ENG SM - 2005.7
1B-87
TENSIONING RAIL
Preceding Work: Removal of timing gear case cover
1. Tensioning rail
3. Tensioning rail pin
2. Plastic guide
4. Guide rail

1. Put the assembly mark at the camshaft sprocket and
the timing chain with the paint (arrow).
3. Remove the tensioning rail (1) from the tensioning rail
pin (3).
Notice
Replace the plastic guide (2) if it is damaged.
For installation, exactly align the plastic guide (2)
with the tensioning rail (1).
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-88
CYLINDER HEAD GUIDE RAIL

1. Chain tensioner
3. Upper guide rail pin
2. Upper guide rail
4. Wrench (special tool)

1. Remove the chain tensioner (1).
2. Turn the exhaust camshaft to the camshaft rotating
direction using the wrench (4) and loosen the timing chain
at upper guide rail (2).
3. Pull out the upper guide rail pin from the guide rail (2).
4. Turn the exhaust camshaft to the opposite direction of
rotation using the wrench.
5. Check for damages at the upper sliding rail and replace
it if necessary. Install the upper guide rail pin.
Installation Notice
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Screw Plug
40 Nm (30 lb-ft)
Tensioner
72 ~ 88 Nm
Assembly
(53 ~ 65 lb-ft)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-89
CRANKCASE GUIDE RAIL

1. Guide rail
3. Guide rail pin
2. Plastic guide
4. Tensioning rail

1. Put the assembly mark at the camshaft sprocket and
the timing chain with the paint (arrow).
3. Remove the guide rail (1) from the guide rail pin (3).
Notice
Replace the plastic guide (2) if damaged.
Connect the plastic guide (2) and the guide rail (1)
by aligning them accurately when installing.
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-90
CRANKSHAFT SPROCKET
Preceding Work: Removal of oil pan
Removal of tensioning rail
Removal of crankcase guide rail
1. Oil pump chain tensioner

2. Oil pump chain bushing
6. Bolt (M8 x 20, 1 piece) / Washer

.................................... 29 ~ 35 Nm (21 ~ 26 lb-ft)
3. Oil pump chain spring
4. Crankshaft sprocket
8. Oil pump
5. Key
9. Oil pump roller chain

10. Timing chain
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-91
Tools Required
W9911 0050B (615 589 01 33 00) Crankshaft Sprocker Puller

1. Put the assembly mark at the crankshaft sprocket (4)
and the timing chain (10) with the paint (arrow).
Notice
Align the assembly marks on cranshaft sprocket and
timing chain. Also, align the assembly marks on
camshaft sprocket and timing chain when installing.
2. Unscrew the bolt (6) and remove the oil pump sprocket
(7) from the oil pump.
Installation Notice
Tightening torque
29 ~ 35 Nm
(21 ~ 26 lb-ft)
3. Remove the oil pump roller chain (9).

4. Remove the oil pump chain tensioner (1), oil pump chain
bushing (2), and the oil pump chain spring (3).
5. Remove the crankshaft sprocket (4) using the crankshaft

sprocket puller W9911 0050B (615 589 01 33 00).
Notice
Make sure not to lose the crankshaft pulley key (5)
when removing.
Install the crankshaft sprocket (4) after warming it
up.
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-92
LUBRICATION SYSTEM
ENGINE OIL SPECIFICATION
1. Drain plug .................................... 25 Nm (18 lb-ft)
3. Engine oil filler cap
2. Oil filter
4. Dipstick gauge
Specifications
Application
Capacity
Quality
Descrition
Min: 7.0L, Max: 9.0L
API SH or above grade
ACEA: A2 or A3
Approved oil by MB Sheet 229.1
Viscosity
Approved oil by MB Sheet 224.1
Replacemant
Initial at 1000 ~ 1500 km, Replace every 15000 km
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-93
REPLACEMENT
1. Install the socket wrench A9910 0050A (103 589 02 09
00) on the oil filter cover (2).
Notice
Tighten the bolts on the socket wrench to remove
the screw cover.
2. Set a wrench on the bolt on the top of socket wrench
and turn it to remove the oil filter cover.
3. Remove the oil filter element.
Notice
Wrap the used filter element with a shop cloth so
that the oil cannot drop on the floor.
4. Remove the drain plug (1) and drain the engine oil
completely.
Notice
To drain the oil easily, remove the oil filler cap (3).
5. Clean the drain plug and reinstall it.
Installation
Tightening torque
25 Nm
Notice
Replace the seal washer with new one.
6. Replace the O-ring (5) on the oil filter cover with new
one.
Notice
When replacing, apply the engine oil on the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover (2) by hands and
then tighten it with the socket wrench A9910 0050A
(103 589 02 09 00).
Installation
Tightening torque
25 Nm
9. Pour the engine oil through the engine oil filler hole.
10. Run the engine and check for oil leakage at normal
operating temperature.
11. Stop the engine and wait for 5 minutes. Check the oil
level and add if necessary.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-94
OIL CIRCULATION
1. Oil pump
19. Oil supply (to intake camshaft)
2. Oil gallery (to oil filter)
20. Oil supply (to exhaust camshaft bearing)
3. Oil filter
21. Oil supply (to intake camshaft bearing)
4. Oil pressure switch
22. Oil gallery (oil supply to exhaust valve tappet)
5. Main oil gallery
23. Oil gallery (oil supply to intake valve tappet)
6. Cylinder head closing cover
24. Camshaft closing cover
7. Oil gallery (at chain tensioner)
25. Ball ( 8 mm)
8. Oil non-return valve
26. Screw plug
9. Chain tensioner
27. Camshaft adjuster
10. Vent (chain tensioner)
28. Front closing cover (intake camshaft)
11. Front closing cover ( 17 mm)
29. Front treaded bushing (exhaust camshaft)
12. Oil gallery (perpendicular to the shaft)
30. Valve tappet
13. Ball ( 6 mm)

14. Oil spray nozzle (timing chain)
a. Oil gallery (from oil pump to oil filter)
15. Oil gallery (at cylinder head)
b. Main oil gallery
16. Ball ( 15mm)
c. Oil return line (oil returns to the oil pan when
17. Oil restriction inner ( 4mm)
replacing the filter element)
18. Oil supply (to exhaust camshaft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-95
ENGINE OIL AND OIL FILTER ELEMENT

Tools Required
A9910 0050A (103 589 02 09 00)
Oil Filter Remover
1. Install the oil filter remover A9910 0050A (103 589 02 09
00) on the oil filter cover.
Notice
Make the screw cover removable by tightening the
bolt at the side of the oil filter remover A9910 0050A
(103 589 02 09 00).
2. Install the wrench to the upper bolt in the oil filter remover
A9910 0050A (103 589 02 09 00) and remove the oil cover
by turning it.
3. Remove the oil filter element.
Notice
Work with a cloth under the vehicle when removing
the oil filter element to not drain the oil.
4. Remove the drain plug (1) and drain the engine oil.
Notice
Leave the oil filler cap open to ease the engine oil
discharge.
5. Tighten the engine oil drain plug after cleaning it.
Installation Notice
Tightening torque
25 Nm (18 lb-ft)
Replace the seal washer with new one.

6. Replace the O-ring in the oil filter cover with new one.
Notice
Apply the engine oil to the O-ring.
7. Insert new oil filter element into the oil filter housing.
8. Temporarily tighten the oil filter cover. Install the oil filter
remover A9910 0050A (103 589 02 09 00), and then
completely tighten it.
Installation Notice
Tightening torque
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
25 Nm (18 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-96
9. Fill up engine oil through the engine oil filler opening (3).
10. Check for oil leaks at normal engine temperature after
starting the engine.
11. Stop the engine and wait 5 minutes.
Check the oil level and fill up as specified if necessary.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-97
OIL FILTER
Preceding Work: Removal of starter motor
Removal of upper intake manifold
1. Coolant line
5. Bolt ................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
2. O-ring ........................................................ Replace
6. Oil filter
3. Clip
7. Gasket ...................................................... Replace
4. Hose
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-98

1. Drain the coolant from the crankcase.
2. Remove the each coolant line and hose.
3. Remove the oil filter bolt and then remove the oil filter.
Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Replace the oil filter gasket.

reverse order.
5. Check engine oil level.
6. Run the engine at idle and check the engine for leaks.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-99
OIL PUMP
.................................... 29 ~ 35 Nm (21 ~ 26 lb-ft)

2. Sprocket (Oil pump drive)
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)

4. Spring pin
5. Oil pump

1. Remove the bolt (1) from the oil pump drive sprocket (2)
and separate the gear and the oil pump drive chain.
Installation Notice
Tightening torque
29 ~ 35 Nm
(21 ~ 26 lb-ft)
2. Unscrew the oil pump mounting bolts (3).

Installation Notice
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Tighten the baffle plate and the oil pump with the two
bolts in right side first, and then tighten the other bolt.
3. Remove the oil pump and oil strainer assembly.
4. Replace the strainer in oil pump if necessary.
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-100
OIL PRESSURE RELIEF VALVE

1. Screw plug .................................. 50 Nm (37 lb-ft)
3. Guide pin
4. Piston

1. Remove the screw plug (1).
Installation Notice
Tightening torque
50 Nm (37 lb-ft)
2. Remove the spring (2), guide pin (3) and the piston (4).
reverse order.
Notice
Dont use the seal for the screw plug.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-101
OIL NON-RETURN VALVE

1. Oil Non-return valve
Functions
The non-return valve prevents the oil in the chain
tensioner from drying up. In other words, it stops
oil-returning in order to prevent the oil in the chain
tensioner from getting dry. As a result, the chain
tensioner can be activated with oil in itself.
1. Remove the non-return valve using a pliers.
2. Insert new non-return valve with hand.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-102
OIL DIPSTICK GUIDE TUBE
1. Oil dipstick level gauge
3. O-ring
2. Oil dipstick guide tube
4. Bolt (M6 x 12, 1 piece) 9 ~ 11 Nm (80 ~ 97 lb-in)

1. Pull out the oil dipstick level gauge (1).
2. Remove the bolt (4) in the upper intake manifold and
remove the oil dipstick guide tube.
Installation Notice
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
3. Install new O-ring to the dipstick guide tube.

reverse order.
5. Check for leaks by starting the engine.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-103
UNIT REPAIR
OIL GALLERY IN CRANKCASE
Preceding Work: Removal of crankshaft
Removal of oil spray nozzle
1. Plug
3. Round bar ...................................... 11 x 750 mm
2. Steel ball
Cleaning Procedure
1. Remove the plug (1) with a screwdriver.
2. Using a round bar (3) and hammer, remove the steel ball
(2).
3. Using the compressed air, blow into the oil galleries and
clean it off.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-104
1. Plug ........................................................... replace
4. Main oil gallery
2. -
5. Screw plug
3. -
Tools Required
A9911 0050B (102 589 12 15 00)
Drift
Sealing Procedure
1. Enlarge the end of main oil gallery (4) to be diameter of
16 mm, depth of 15 mm.
2. Using an M16 x 1.5 thread (tap), make the thread at the
end of main oil gallery (4).
3. Throughly clean the oil gallery with compressed air and
tighten the screw plug (M16 x 1.5) after applying sealing
bond on it.
4. Apply Loctite 270 on new plug and tighten to the hole
until the drift A9911 0050B (102 589 12 15 00) is stopped
after inserting new plug into the drift.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-105
OIL GALLERY IN CYLINDER HEAD

Preceding Work: Removal of cylinder head
Removal of camshaft
Removal of tappet
1. Screw plug ................................... 15 Nm (11 lb-ft)
3. Steel ball ( 8 mm)
2. Seal
Cleaning Procedure
1. Remove the screw plug (1) and the seal (2).
Installation
Tightening torque
15 Nm (11 lb-ft)
Replace the seal with new one.

2. Clean the oil gallery using the compressed air.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-106
Sealing Procedure
1. Remove the screw plug (1) and the seal.
Installation
Tightening torque
15 Nm (11 lb-ft)
2. Remove the steel ball from the oil gallery (4), (5), (6) and
(7) using the round bar (12, 6 x 700 mm).
3. Remove the plug (8) using the screw driver.
4. Enlarge the oil gallery at the rear of the cylinder head to

be diameter 9mm, depth 8mm.
5. Tap in the steel ball (3) from the side to the oil gallery
using the punch (13).
6. Pull out the steel ball (3) using the round bar (12).
7. Enlarge the oil gallery to be diameter 9mm, depth 8 mm.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-107
8. Make a screw hole at the oil gallery using M10 x 1 thread.
9. All the oil gallery should be cleaned with the compressed air.
10. Apply the Loctite 270 to new plug and press in using a suitable
drift (arrow).
11. Tighten the screw plug with the seal (arrow).
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-108
CORE PLUGS IN CRANKCASE

Preceding Work: Draining of the coolant
1. Core plug ................................................... replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-109
Tools Required
W9911 0010B (102 589 00 15 00)
Drift
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side comes
out using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift W9911 0010B (102 589

00 15 00).
Notice
Wait for about 45 minutes before filling the coolant
so that the Loctite hardens.
6. Warm up the engine and check the coolant for leaks.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-110
CYLINDER BORE
Group Code Letter and Cylinder Bore Size

Group Code Letter of Cylinder
Piston Type to be Used
A or X
Cylinder Bore Size (mm)

89.900 ~ 90.906
A, X or B
89.906 ~ 89.912
X or B
89.912 ~ 89.918
X+5
X+5
89.950 ~ 89.968
X + 10
X + 10
90.000 ~ 90.018
Type
Group Code Letter1)
Standard size 89.9
Cylinder Bore Size (mm)

89.900 ~ 90.906
89.906 ~ 89.912
89.912 ~ 89.918
1st repair size
90.150 ~ 90.156
(Standard size + 0.25)
89.156 ~ 90.162
90.162 ~ 90.168
2nd repair size
90.400 ~ 90.406
(Standard size + 0.5)
90.406 ~ 90.412
90.412 ~ 90.418
Repair Size
1)
The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-111

Wear limit in longitudinal and transverse direction
Permissible deviation of cylinder out-of-round
0.1 mm
When new
0.007 mm
Wear limit
0.05 mm
Permissible deviation of rectangular cylinder height (except chamfered area)

Basic peak-to-valley height after final honing and brushing
0.05 mm
0.003 ~ 0.006 mm
Chamfer angle
60
Honing angle
50 10
Measurement of Cylinder Bore

1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore size
in axial and transverse direction at three points (1, 2, 3).
1,2,3. Measuring points

A. Axial direction
B. Transverse direction
a. Location of the No.1 piston ring at TDC
b. Location of the piston BDC
c. Location of the oil ring at BDC
Chamfer Angle
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-112
CRANKCASE MATING SURFACE

282.25 ~ 282.35 mm
Height of the crankcase H (when new)
281.95 mm
Minimum height after milling

Flatness
Crankcase upper mating surface
0.03 mm
Crankcase lower mating surface
0.04 mm
Permissible deviation of parallelism of the

upper to lower mating surface
Axial direction
0.1 mm
Transverse direction
0.05 mm
Peak-to-valley height
Crankcase upper mating surface
0.005 ~ 0.020 mm
Crankcase lower mating surface
0.025 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-113
Chamfering Procedure
1. Chamfer angle : 60
2. Polish the lower chamfered area evenly with a grinder

after finishing the chamfering with a suitable tool (e.g.,
hand milling cutter).
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-114
CYLINDER HEAD MATING SURFACE

Preceding Work: Removal of valves

135.9 ~ 136.0 mm
Overall height of cylinder head
135.5 mm
Minimum height after machining

Flatness
Distance T
(between camshaft bearing
and valve stem)
Axial direction
0.08 mm
Transverse direction
0.0 mm
Standard size
Repair size
Intake
24.21 ~ 24.75 mm
Exhaust
22.21 ~ 22.75 mm
Intake
23.96 ~ 24.51 mm
Exhaust
21.96 ~ 22.51 mm
Notice
Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-115
Measurement of Mating Surface

1. Measure the height (H) of the cylinder head (refer to
Service data standard).
2. Check the mating surface of the cylinder head.
3. Mill the sharp edge of the combustion chamber.
4. Re-measure the height (H) of the cylinder head.
5. Seal the intake and exhaust valves.
6. Measure the dimension (T) between the camshaft bearing
and the valve system (refer to Service data standard).
7. Mill the cylinder head valve seat (refer to Service data
standard).
Universal Tool
Sceledum, Type RTY
Surface Grinding Machine
Roaro
Schio/Italy
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-116
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Nm
Lb-Ft
Lb-In
22.5 ~ 27.5
16.6 ~ 20.3
35
26
40.5 ~ 49.5
29.9 ~ 36.5
9 ~ 11
80 ~ 97
60 ~ 70
44 ~ 52
Camshaft bearing cap bolt
22.5 ~ 27.5
16.6 ~ 20.3
Chain tensioner assembly
72 ~ 88
53 ~ 65
Chain tensioner screw plug
40
30
40 + 5
30 + 3.7
90 + 10
90 + 10
22.5 ~ 27.5
16.6 ~ 20.3
50 ~ 60
37 ~ 44
90 + 5
90 + 5
9 - 11
80 ~ 97
Cylinder block drain plug
30
22
Cylinder head bolt
55
41
+90
+90
+90
+90
9 ~ 11
80 ~ 97
Cylinder head front cover bolt
22.5 ~ 27.5
16.6 ~ 20.3
Engine mounting bracket nut
70
52
18 ~ 22
13 ~ 16
90 5
90 5
30
22
45 + 5
33 + 3.7
90 + 10
90 + 10
21 ~ 25
15 ~ 18
25
18
9 ~ 11
80 ~ 97
18 ~ 22
13 ~ 16
90 5
90 5
Lower engine mounting nut
38
28
Oil dipstick guide tube bolt
9 ~ 11
80 ~ 97
22.5 ~ 27.5
16.6 ~ 20.3
A/C bracket bolt

Armature bolt in camshaft actuator
Belt tensioning pulley nut
Camshaft actuator bolt
Camshaft adjuster mounting nut
Connecting rod bearing cap bolt
Cooling fan bracket bolt

Crankshaft bearing cap bolt
Crankshaft sealing rear cover mounting bolt
Cylinder head cover bolt
Exhaust camshaft sprocker bolt
Exhaust manifold and pipe

Flywheel mounting bolt
Fuel feed and return hose to fuel rail

Generator carrier bolt
Intake air duct nut
Intake flange shaft bolt
Oil drain plug
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-117
Fastener Tightening Specifications (Contd)

Application
Nm
Lb-Ft
Lb-In
22.5 ~ 27.5
16.6 ~ 20.3
Oil filter cover
25
18
Oil gallery screw plug in cylinder head
15
11
M10
40
30
M8
22.5 ~ 27.5
16.6 ~ 20.3
M6
9 ~ 11
80 ~ 97
50
37
29 ~ 35
21 ~ 26
Oil pump mounting bolt
22.5 ~ 27.5
16.6 ~ 20.3
Oil pump sprocket bolt
29 ~ 35
21 ~ 26
9 ~ 11
80 ~ 97
22.5 ~ 27.5
16.6 ~ 20.3
26 ~ 32
19 ~ 24
M8
22.5 ~ 27.5
16.6 ~ 20.3
M6
9 ~ 11
80 ~ 97
42
31
Transmission mounting nut
54 ~ 68
40 ~ 50
Under cover
28 ~ 47
21 ~ 35
70
52
180 ~ 220
133 ~ 162
90 + 10
90 + 10
22.5 ~ 27.5
16.6 ~ 20.3
Oil filter bolt
Oil pan bolt
Oil pressure relief valve screw plug

Oil pump drive sprocket bolt
Spark plug cover bolt

Steering pump bolt
Tensioning device bolt
Timing gear case cover bolt
Torque converter mounting bolt
Upper engine mounting nut

Vibration damper center bolt
Water pump pulley bolt
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-118

000 589 58 43 00
A9917 0101B (111 589 01 59 00)
Chain Assembly
Supporting Bar
W9911 0010B (102 589 00 15 00)
A9917 0111B (111 589 18 61 00)
Drift
Lever Pusher
A9911 0050B (102 589 12 15 00)
A9917 0121B (111 589 25 63 00)
Drift
Thrust Piece
A9910 0050A (103 589 02 09 00)
A9913 0061B (116 589 01 34 00)
Oil Filter Remover
Threaded Pin
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1B-119
A9917 0171B (119 589 00 43 00)
A9910 0150A (603 589 00 40 00)
Drift
Fan Clutch Holder
A9911 0060B (601 589 03 14 00)
W9910 0150A (615 589 01 33 00)
Crankshaft Front Seal Installer
Crankshaft Sprocket Puller
A9910 0150B (602 589 00 40 00)
A9912 0080B (617 589 00 10 00)
Engine Lock
Allen Wrench Socket
W9911 0020B (601 589 03 43 00)
A9911 0012B (DW110-090)
Crankshaft Rear Seal Installer
Connecting Hose
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1B-120

A9917 0012B (DW110-120)
Holding Pin
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-1
SECTION
00 1D
ENGINE COOLING
Table of Contents
DESCRIPTION AND OPERATION ......... 1D-2
General description ..........................
Radiator ............................................
Coolant reservoir ..............................
Thermostat ........................................
Water pump .......................................
Electric cooling fan ...........................
A/C Off or Non-AC model .................
A/C On ..............................................
Engine coolant temperature sensor .
Coolant temperature gauge .............
1D-2
1D-2
1D-2
1D-2
1D-3
1D-3
1D-3
1D-3
1D-3
1D-3
COMPONENT LOCATOR ...................... 1D-4

Gasoline engine ................................ 1D-4
DIAGNOSTIC INFORMATION AND
PROCEDURE ........................................ 1D-5
REPAIR INSTRUCTIONS ....................... 1D-8

ON-VEHICLE SERVICE ......................... 1D-8
Coolant drain and fill up ................... 1D-8
Coolant connection fitting ............... 1D-10
Water pump ..................................... 1D-12
Oil cooler pipe line .......................... 1D-14
Thermostat ...................................... 1D-15
Cooling fan and viscous clutch ....... 1D-16
Cooling fan shroud ......................... 1D-18
Radiator .......................................... 1D-20
General specifications .................... 1D-22
SPECIFICATION .................................. 1D-23
Fastener tightening specifications . 1D-23
SPECIAL TOOLS AND EQUIPMENT .. 1D-24
Cooling system diagnosis ................. 1D-5

Thermostat test ................................. 1D-7
System leakage test ......................... 1D-7
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-2

GENERAL DESCRIPTION
The cooling system maintains the engine temperature at
an efficient level during all engine operating conditions.
When the engine is cold, the cooling system cools the
engine slowly or not at all. This slow cooling of the engine
allows the engine to warm up quickly.
The cooling system includes a radiator and recovery
subsystem, cooling fans, a thermostat and housing, a
water pump, and a water pump drive belt. The timing belt
drives the water pump.
All components must function properly for the cooling
system to operation. The water pump draws the coolant
from the radiator. The coolant then circulates through water
jackets in the engine block, the intake manifold, and the
cylinder head. When the coolant reaches the operating
temperature of the thermostat, the thermostat opens. The
coolant then goes back to the radiator where it cools.
This system directs some coolant through the hoses to
the heat core. This provides for heating and defrosting.
The coolant reservoir is connected to the radiator to recover the coolant displaced by expansion from the high
temperatures. The coolant reservoir maintains the correct coolant level.
The cooling system for this vehicle has no radiator cap or
filler neck. The coolant is added to the cooling system
through the coolant reservoir.
RADIATOR
This vehicle has a lightweight tube-and-fin aluminum
radiator. Plastic tanks are mounted on the upper and the
lower sides of the radiator core.
the coolant reservoir. The air trapped in the radiator and

the engine is degassed into the coolant reservoir.
When the engine stops, the engine coolant cools and
contracts. The displaced engine coolant is then drawn
back into the radiator and the engine. This keeps the
radiator filled with the coolant to the desired level at all
times and increases the cooling efficiency.
Maintain the coolant level between the MIN and MAX
marks on the coolant reservoir when the system is cold.
THERMOSTAT
A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system. The thermostat is mounted in the thermostat housing to the front
of the cylinder head.
The thermostat stops the flow of the engine coolant from
the engine to the radiator to provide faster warm-up, and
to regulate the coolant temperature. The thermostat remains closed while the engine coolant is cold, preventing
circulation of the engine coolant through the radiator. At
this point, the engine coolant is allowed to circulate only
throughout the heater core to warm it quickly and evenly.
As the engine warms, the thermostat opens. This allows
the engine coolant to flow through the radiator where the
heat is dissipated. This opening and closing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature
operating limits.
The wax pellet in the thermostat is hermetically sealed in
a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled.
COOLANT RESERVOIR
As the vehicle is driven and the engine warms, the engine

coolant temperature increases. When the engine coolant
reaches a specified temperature, the wax pellet element
in the thermostat expands and exerts pressure against
the metal case, forcing the valve open. This allows the
engine coolant to flow through the engine cooling system
and cool the engine.
The coolant reservoir is a transparent plastic reservoir,

similar to the windshield washer reservoir.
As the wax pellet cools, the contraction allows a spring

to close the valve.
The coolant reservoir is connected to the radiator by a

hose and to the engine cooling system by another hose.
As the vehicle is driven, the engine coolant heats and
expands. The portion of the engine coolant displaced by
this expansion flows from the radiator and the engine into
The thermostat begins to open at 82C (180F) and is

fully open at 95C (203F). The thermostat closes at 80C
(176F).
On vehicles equipped with automatic transaxles, the

transaxle fluid cooler lines run through the radiator tank.
A radiator drain plug is on this radiator.
To drain the cooling system, open the drain plug.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-3
WATER PUMP
The belt-driven centrifugal water pump consists of an
impeller, a drive shaft, and a belt pulley.
The impeller is supported by a completely sealed bearing.
The water pump is serviced as an assembly and, therefore, cannot be disassembled.
ELECTRIC COOLING FAN

Caution
Keep hands, tools, and clothing away from the engine
cooling fans to help prevent personal injury. This fan
is electric and can turn on even when the engine is
not running.
Caution
f a fan blade is bent or damaged in any way, no attempt
should be made to repair or reuse the damaged part.
A bent or damaged fan assembly should always be
replaced with a new one to prevent possible injury.
The cooling fans are mounted behind the radiator in the
engine compartment. The electric cooling fans increase
the flow of air across the radiator fins and across the
condenser on air conditioned (A/C)-equipped vehicles.
This helps to speed cooling when the vehicle is at idle or
moving at low speeds.
All models have two fans. The main fan is 320 mm (12.6
inches) in diameter with seven blades to aid the airflow
through the radiator and the condenser. An electric motor
attached to the radiator support drives the fan. The auxiliary fan is 320 mm (12.6 inches) in diameter.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
A/C OFF OR NON-AC MODEL

The cooling fans are actuated by the engine control
module (ECM) using a low-speed cooling fan relay, a
high-speed cooling fan relay and a cooling fan motor
relay.
The ECM will turn the cooling fans on at low speed
when the coolant temperature reaches 95C (203F)
and at high speed when the coolant temperature
reaches 105C (221F).
The ECM will change the cooling fans from high peed
to low speed at 100C (212F) and will turn the cooling
fans off at 90C (194F).
A/C ON
The ECM will turn the cooling fans on at low speed
when the A/C system is on. The ECM will change to
high speed when the high side A/C pressure reaches
1860 kPa (269.8 psi).
The cooling fans will return to low speed when the
high side A/C pressure reaches 1378 kPa (199.8 psi).
ENGINE COOLANT TEMPERATURE SENSOR

The Engine Coolant Temperature (ECT) sensor uses a
temperature to control the signal voltage to the Engine
Control Module (ECM).
COOLANT TEMPERATURE
GAUGE
The coolant temperature gauge controls the instrument
panel temperature indicator. The coolant temperature
gauge is located with ECT sensor.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-4
COMPONENT LOCATOR
GASOLINE ENGINE
1. Radiator
10. Bolt (M6, 4 pieces)
19. Clamp
2. Electric fan
11. Upper radiator insulator
20. Clamp
3. Shroud
12. Lower radiator insulator
21. Make up hose holder
4. Deaeration tube
13. Plate
22. Reserver tank
5. Clamp
14. Clip
23. Bolt (M6, 2 piece)
6. Deaeration hose (radiator)
15. Inlet hose
24. Cooling fan
7. Electric fan mounting bracket
16. Outlet hose
25. Viscous clutch
17. 3 way hose
18. Deaeration hose (reserver tank)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-5

COOLING SYSTEM DIAGNOSIS
Engine Overheats
Checks
Action
Check for a loss of the coolant
Add the coolant.
Check for a weak coolant solution.
Confirm that the coolant solution is a 50/50 mixture of

ethylene glycol and water.
Check the front of the radiator for any dirt, any leaves,
or any insects.
Clean the front of the radiator.
Check for leakage from the hoses, the water pump, the
heater, the thermostat housing, the radiator, the core
plugs, or the head gasket.
Replace any damaged components.
Check for a faulty thermostat.
Replace a damaged thermostat.
Check for retarded ignition timing.
Perform an ECM code diagnosis. Confirm the integrity

of the timing chain.
Check for an improperly operating electric cooling fan.
Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted.
Replace any damaged radiator hoses.
Check for a faulty water pump.
Replace a faulty water pump.
Check for a faulty coolant reservoir cap.
Replace a faulty coolant reservoir cap.
Check for a cylinder head or an engine block that is

cracked or plugged.
Repair the damaged cylinder head or the damage

engine block.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-6
Loss of Coolant
Checks
Action
Check for a leak in the radiator.
Replace a damaged radiator.
Check for a leak in the following locations:
Replace the following parts, as needed.
Coolant reservoir.
Coolant reservoir.
Hose.
Hose.
Check for loose or damaged radiator hoses, heater

hoses, and connections.
Reseat the hoses.

Replace the hoses or the clamps.
Check for leaks in the water pump seal.
Replace the water pump seal.
Check for leaks in the water pump gasket.
Replace the water pump gasket.
Check for an improper cylinder head torque.

Check for leaks in the following locations:
Tighten the cylinder head bolts to specifications.

Replace the cylinder head gasket, if needed.
Intake manifold.
Repair or replace any components, as needed, to

correct the leak.
Cylinder head gasket.

Cylinder block plug.
Heater core.
Radiator drain plug.
Engine Fails to Reach Normal Operating Temperature or Cool Air from

the Heater
Checks
Action
Check to determine if the thermostat is stuck open or is

the wrong type of thermostat.
Install a new thermostat of the correct type and heat range.
Check the coolant level to determine if it is below the

LOW mark on the coolant reservoir.
Add sufficient coolant to raise the fluid to the specified

mark on the coolant reservoir.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-7
SYSTEM LEAKAGE TEST

Tools Required
A9921 0012A (124 589 15 21 00) Leakage Tester
Test Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, cap must not be opened unless
the coolant temperature is below 90 C (194 F).
2. Fill coolant up to upper edge (arrow) of reservoir.
3. Connect the leakage tester A9921 0012A (124 589 15 21
00) to the reservoir filler cap and apply 1.4 bar of pressure.
4. If the pressure on the tester drops, check leakage at the
all coolant hoses and pipes and each connections.
Replace or retighten if necessary.
THERMOSTAT TEST
Test Procedure
1. Remove the thermostat from the vehicle. Refer to
Thermostat in this section.
2. Make sure the valve spring is tight when the thermostat
is closed. If the spring is not tight, replace the thermostat.
3. Suspend the thermostat and a thermometer in a pan of
50/50 mixture of ethylene glycol and water. Do not let
the thermostat or the thermometer rest on the bottom of
the pan. The uneven concentration of heat on the bottom
could result in inaccurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of the
heated solution.
6. The thermostat should begin to open at 82C (180F)
and it should be fully be fully open at 95C (203F).
If it does not open at these temperatures, replace the
thermostat.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-8
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
COOLANT DRAIN AND FILL UP
Draining & Filling up Procedure
1. Loosen the cap a little and release pressure and remove
the cap.
Notice
For the risk of scalding, the cap must not be opened
unless the coolant temperature is below 90C (194F).
2. Loosen the radiator hose and drain the coolant.
Notice
Collect coolant by using a proper container.
3. Drain the coolant from the crankcase by inserting a hose

(dia. 14 mm) onto the drain bolt on the side of crankcase
(exhaust manifold) and by loosening the plug.
Notice
Just loosen the drain plug to drain the coolant and
do not remove the plug completely.
Collect coolant by using proper container.
4. After complete draining of the coolant, remove the hose
connector to drain plug and reinstall the drain plug.
Installation Notice
Tightening torque
30 Nm (22 lb-ft)
5. Tighten the radiator lower drain cock.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-9
6. Remove the de-aeration hose clamp in the coolant pump
and remove the de-aeration hose.
7. Fill up the coolant through the coolant reservoir tank.
Notice
Match the anti-freeze and the water ratio to
50 : 50.
Supplement the coolant until the coolant overflows
to the de-aeration hose.
8. Insert the de-aeration hose and completely tighten the

clamp.
9. Check the coolant level in the coolant reservoir tank.
10. Warm up (until thermostat is opened) the engine and
recheck the coolant level in the reservoir tank and fill up
the coolant if necessary.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-10
COOLANT CONNECTION FITTING

Preceding Work: Removal of cooling fan shroud
1. Bolt (M8 X 100, 2 pieces)

........................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
2. Engine hanger bracket
4. O-ring
5. Hose mounting clamp
6. Hose
3. Coolant outlet port
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-11

1. Drain coolant from the radiator.
2. Remove the hose mounting clamp (5) and disconnect
the coolant hose (6).
3. Remove the two bolts (1), the engine hanger bracket (2)
and coolant outlet port (3).
Installation Notice
Specified value
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Replace the O-ring with new one.

reverse order.
5. Fill up the coolant as specified.
6. Check the leaks in the cooling system.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-12
WATER PUMP
Preceding Work: Removal of V-belt
Removal of air admission housing
1. Air admission housing
8. Coolant hose
2. Oil cooler pipe line
9. Inlet coolant hose
3. Seal ........................................................... replace
10. Water pump
4. Bolt ............................... 9 ~ 11 Nm (80 ~ 97 lb-in)
11. Bolt ................ 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
5. Coolant hose
12. Dowel sleeve
6. Coolant hose
13. Seal ........................................................... replace
7. Outlet coolant hose
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-13

1. Drain the coolant.
2. Disconnect the water pump wire connector.
3. Loosen the hose clip and disconnect all hoses from the
water pump
4. Remove the coolant line bolts (4) and then remove the
coolant line (2).
Installation
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
Replace the seal (3).

5. Remove the mounting bolts (11) and carefully pull out
water pump (10).
Installation
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
Replace the seal (13).

reverse order.
7. Fill up coolant.
8. Do coolant system leakage test.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-14
OIL COOLER PIPE LINE

Preceding Work: Removal of upper intake manifold
1. Bolt (M6 X 35, 1 piece)
3. Oil cooler pipe line
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
4. O-ring ........................................................ Replace

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)

2. Unscrew the bolts (1, 2) and remove the oil cooler pipe
line (3).
Installation
Tightening Torque
9 ~ 11 Nm
(80 ~ 97 lb-in)

reverse order.
4. Fill up the coolant as specified.
5. Check the leaks in the cooling system.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-15
THERMOSTAT
1. Thermostat cover
2. Thermostat
...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
3. O-ring
6. Hose mounting clamp
4. Thermostat cover bracket
7. Heater hose

1. Drain the coolant from the radiator.
2. Loosen the hose mounting clamp (6) and remove the
heater hose (7).
3. Unscrew the three bolts (5) and remove the thermostat
cover bracket, thermostat cover and the thermostat in
order.
Installation
Tightening Torque
9 ~ 11 Nm
(80 ~ 97 lb-ft)
Do not separate the thermostat cover and thermostat.

4. Replace the O-ring if necessary.
5. Check the leakage in the cooling system.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-16
COOLING FAN AND VISCOUS CLUTCH


2. Viscous clutch
3. Cooling fan
4. Bolt (M6 X 12, 4 piece)

...................................... 9 ~ 11 Nm (80 ~ 97 lb-in)
....................... 40.5 ~ 49.5 Nm (29.8 ~ 36.5 lb-in)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-17
Tools Required
A9910 0150A (603 589 00 40 00)
Fan Clutch Holder

1. Remove the engine hanger bracket bolts.
Installation
Tightening torque
22.5 ~ 27.5 Nm
(16.6 ~ 20.3 lb-ft)
2. Remove the engine hanger bracket.

3. Remove the cooling fan bolts.
Installation
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-in)
4. Hold the cooling fan pulley using the fan clutch holder
A9910 0150A (603 589 00 40 00).
5. Remove the viscous clutch mounting bolts and viscous

clutch.
Installation
Tightening torque
40.5 ~ 49.5 Nm
(29.8 ~ 36.5 lb-ft)
Important
There are two chambers in the viscous clutch. Be
sure to make the viscous clutch stand on the ground
not to flow silicone oil into another chamber in the
viscous clutch. Do not lay down the clutch.
reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-18
COOLING FAN SHROUD
1. Fan shroud assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2. Bolt ................................ 3 ~ 7 Nm (27 ~ 62 lb-in)
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-19

1. Pull out the 2 clips (1) from the fan shroud assembly.
2. Remove the lower fan shroud (2).
Notice
For installation, exactly align the lower fan shroud
pin into the hole of the fan shroud assembly (4) and
insert the clips.
3. Remove the bolts (3) and then remove the cooling fan
shroud assembly (4).
Installation
Tightening torque
3 ~ 7 Nm
(27 ~ 62 lb-in)

reverse order.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-20
RADIATOR
1. Deaeration hose
5. Lower radiator insulator
2. Radiator
6. Plate
3. Inlet hose
7. Clip
4. Bolt
8. Upper radiator insulator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-21

1. Drain coolant from the radiator.
2. Remove the each coolant hoses.
3. Remove the upper and lower automatic transmission oil

cooling pipes from radiator.
Installation
Tightening torque
25 ~ 35 Nm
(18 ~ 26 lb-ft)
4. Remove the mounting bolt (9) from the automatic

transmission oil cooler pipe (5) and then disconnect the
cooler pipe (5).
Installation
Tightening torque
3 ~ 7 Nm
(27 ~ 62 lb-in)
5. Remove the cooling fan shroud bolts and cooling fan

shroud.
Installation
Tightening torque
3 ~ 7 Nm
(27 ~ 62 lb-in)
6. Remove the radiator grille mounting screw and radiator

grille.
7. Remove the front and upper member mounting bolts and

front end upper member.
Installation
Tightening torque
30 ~ 40 Nm
(22 ~ 30 lb-ft)
8. Remove the radiator

9. Check the radiator pin for crack, damage, leakage and
bending and replace it if necessary.
reverse order.
11. Check for leakage in the cooling system.
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-22
SPECIFICATION
GENERAL SPECIFICATIONS
Application
Unit
Gasoline Engine
Cooling system
Type
Water cooling forced

circulation
Coolant
Capacity
11.3
Thermostat
Type
Wax pellet type
Initial opening temp.
C (F)
82 (180)
Fully opening temp.
C (F)
95 (203)
Fully closing temp.
C (F)
80 (176)
mm
Type
Electric cooling
Blades
mm
320
Low speed ON temp.
C (F)
95 (203)
Low speed OFF temp.
C (F)
90 (194)
High speed ON temp.
C (F)
105 (221)
High speed OFF temp.
C (F)
100 (212)
High speed ON temp. (By A/C pressure)
kPa (psi)
269.8 (1860)
Pressure valve opening pressure
kPa (psi)
118 ~ 147 (17.1 ~ 21.3)
Vacuum valve opening pressure
kPa (psi)
9.8 (1.4)
Turbo centrifugal
mm
65
Impeller blades
Type
Cross-flow
Core width
mm
701
Core height
mm
372
Core thickness
mm
18
Minimum radiation capability
Kcal/h
45,000
Resistance (at 50C (122F))
185.2
47.4
Stroke
Cooling fan
Diameter
Coolant reservoir
Water pump
Type
Impeller diameter
Radiator
Coolant temperature
gauge
28.2
Engine coolant
temperature sensor
3.33 ~ 37.8
0.32 ~ 0.35
Anti-freeze agent
Type
ALUTEC-P78
Mixture of water and good quality ethylene

glycol-base anti-freeze
50 : 50
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1D-23

Application
Nm
Lb-Ft
Lb-In
20
15
3~7
27 ~ 62
30
22
Cooling fan bolt
9 ~ 11
80 ~ 97
Cooling fan shroud bolt
3~7
27 ~ 62
22.5 ~ 27.5
16.6 ~ 20.3
Radiator mounting bracket bolt
3~7
27 ~ 62
Thermostat cover bracket bolt
9 ~ 11
80 ~ 97
Viscous clutch mounting bolt
40.5 ~ 49.5
29.8 ~ 36.5
Water pump mounting bolt
22.5 ~ 27.5
16.6 ~ 20.3
Automatic transmission oil cooler pipe

Automatic transmission oil cooler pipe mounting bolt
Coolant drain plug
Engine hanger bracket and coolant outlet port bolt
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1D-24

A9910 0060A (111 589 00 40 00)
A9910 0070A (111 589 02 01 00)
Holder
Open End Wrench
A9921 0012A (124 589 15 21 00)
A9910 0150A (603 589 00 40 00)
Leakage Tester
Fan Clutch Holder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE MECHANICAL
M162 GSL ENG SM - 2005.7
1F-1
SECTION
00 1F
ENGINE CONTROLS
Table of Contents
ENGINE AND ECM PROBLEM CHECK
REPORT ................................................. 1F-3
Vehicle and customer information ..... 1F-3
Mil information .................................... 1F-3
Problem description ........................... 1F-3
Condition when problem occurs ........ 1F-3
DIAGNOSTIC INFORMATION AND
PROCEDURE ......................................... 1F-4
Failure code diagnosis ...................... 1F-4
IGNITION SYSTEM ................................ 1F-8
Ignition coil ......................................... 1F-9
Crankshaft position (CKP) sensor ... 1F-11
Camshaft position (CMP) sensor..... 1F-14
Camshaft actuator ........................... 1F-18
Knock Sensor (KS) .......................... 1F-20
Spark plug ........................................ 1F-22
System voltage ................................ 1F-24
Ignition switch ................................... 1F-25
FUEL SYSTEM ..................................... 1F-26
Fuel pump ........................................ 1F-27
Fuel injector ..................................... 1F-30
Purge control valve .......................... 1F-34
Fuel rail ............................................ 1F-36
Fuel pressure regulator ................... 1F-38
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
INDUCTION SYSTEM .......................... 1F-41

Throttle valve actuator ..................... 1F-40
Hot Film Air Mass (HFM) sensor ...... 1F-43
Engine Coolant Temperature
(ECT) sensor ................................... 1F-47
Accelerator pedal module ................ 1F-51
Cooling fan ....................................... 1F-54
A/C compressor relay ...................... 1F-55
Cruise control switch ........................ 1F-56
Resonance flap ................................ 1F-57
Stop lamp switch .............................. 1F-58
EXHAUST SYSTEM .............................. 1F-60
Catalytic converter ........................... 1F-60
Oxygen sensor ................................. 1F-61
ENGINE CONTROL MODULE ............. 1F-66
Serial data communication .............. 1F-67
Internal failure .................................. 1F-69
Electronic throttle controller safety
malfunction ....................................... 1F-70
Immobilizer ....................................... 1F-72
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-2
MAINTENANCE AND REPAIR .............. 1F-73

ON-VEHICLE SERVICE ........................ 1F-73
Discharging the pressure in fuel
system .............................................. 1F-73
Fuel pump ........................................ 1F-73
Fuel filter .......................................... 1F-74
Fuel tank .......................................... 1F-75
Fuel pressure regulator ................... 1F-78
Fuel rail and injectors ...................... 1F-79
Engine coolant temperature
sensor .............................................. 1F-80
Throttle body (integrated with the
actuator) ........................................... 1F-81
Hot Film Air Mass (HFM) sensor ...... 1F-82
Knock sensor ................................... 1F-82
Pedal position sensor ...................... 1F-83
Oxygen sensor ................................. 1F-83
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Purge control valve .......................... 1F-84

Canister ............................................ 1F-84
Engine control module ..................... 1F-85
Camshaft position sensor ................ 1F-85
Crankshaft position sensor .............. 1F-85
SCHEMATIC AND ROUTING
DIAGRAMS ........................................... 1F-86
Diagnosis circuit ............................... 1F-86
ECU (GSL G32) ............................... 1F-87
SPECIFICATIONS ................................. 1F-90
Engine data display table ................ 1F-90
Fastener tightening specifications .. 1F-91
Fuel system specification ................ 1F-92
Temperature vs resistance .............. 1F-92
SPECIAL TOOLS AND EQUIPMENT ... 1F-93
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-3
ENGINE AND ECM PROBLEM CHECK REPORT

VEHICLE AND CUSTOMER INFORMATION
Date Problem Occurred
Customer Name
Vehicle Model
Driver Name
VIN
Purchase date
Engine Model
License No.
Mileage
Km
miles
MIL INFORMATION
Condition of MIL
Remains on
Sometimes illuminates
Does not illuminate
DTC inspection
Normal
Malfunction code(s) (code
(if available)
Freeze Frame data (
PROBLEM DESCRIPTION
Engine Does Not Start
No cranking
Hard to Start
Slow cranking
No initial combustion
No complete combustion
Others
Poor Idling
Incorrect first Idle
Abnormal idle rpm
High (rpm)
Low (rpm)
Idling Unstable Others

Poor Driveability
Engine Stall
Hesitation
Back fire
Muffler explosion (after-burning)
Surging
Knocking
Poor performance
Soon after starting
Other
After accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D or D to N
At full steering Others
Others
CONDITION WHEN PROBLEM OCCURS

Constant Intermittent (times per day/month) Once only Others
Problem Frequency
Fine
Weather
Hot
Warm
Ambient Temperature
Highway
Suburbs
Place
Rough Road
Others
Cold
Warming Up
Any temp.
Others
Starting
Just after starting (min.)
Engine Temperature
Engine Operation
Cloudy Rainy Snowy Various/Others
Constant speed
Acceleration
A/C switch ON/OFF
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Cool
Cold (approx.____F/____C)
Inner City
Uphill Downhill
Before warming up
Idling
After warm-up
Racing
Deceleration
Other
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Driving
1F-4

FAILURE CODE DIAGNOSIS
Clearing Failure Codes
Notice: To prevent Engine Control Module (ECM) damage, the key must be OFF when disconnecting or reconnecting
the power to the ECM (for example battery cable, ECM pigtail connector, ECM fuse, jumper cables, etc.)
Parameters listed in the table may not be exactly the same as your reading due to the type of instrument or other
factors. If a failure code is displayed during the TROUBLE CODE in scan tool check mode, check the circuit for the
code listed in the table below. For details of each code, turn to the page referred to under the See Page for the respective Failure Code in the below table.
Failure codes should be cleared after repairs have been completed.
Failure Codes Table

Failure Code See Page
Description
00
1F-56
Engine coolant temperature sensor low voltage
01
1F-56
Engine coolant temperature sensor high voltage
02
1F-56
Engine coolant temperature sensor plausibility
03
1F-52
Intake air temperature sensor low voltage
04
1F-52
Intake air temperature sensor high voltage
05
1F-52
Intake air temperature sensor plausibility
06
1F-56
Engine coolant temperature insufficient for closed loop fuel control
08
1F-28
System voltage too low
09
1F-52
Mass air flow sensor plausibility
10
1F-52
Mass air flow sensor low voltage
11
1F-52
Mass air flow sensor high voltage
17
1F-13
Crankshaft position sensor signal failure (no engine revolution signal)
18
1F-13
Crankshaft position sensor signal failure (rpm > max. value)
19
1F-17
Camshaft position senosr signal: No.1 cylinder recognition failure
20
1F-13
Crankshaft position sensor signal failure (gap recognition failure)
21
1F-79
Transmission coding failure
23
1F-77
CAN communication failure: ASR/MSR
24
1F-77
CAN communication failure: ABS
25
1F-82
Communication with transponder missing
26
1F-77
CAN communication failure: TCU (A/T only)
27
1F-78
CAN communication failure: TOD (E32 only)
29
1F-78
CAN communication failure: ID 200h not plausible
30
1F-78
CAN communication failure: ID 208h not plausible
31
1F-78
CAN communication failure: communication initialization failure
32
1F-68
Engine rpm output circuit short circuit to battery
33
1F-68
Engine rpm output circuit short circuit to ground or open
34
1F-33
Fuel pump relay short circuit to battery
35
1F-33
Fuel pump relay short circuit to ground or open
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-5
Failure Codes Table (Contd)

Description
40
1F-41
Purge control valve short circuit to battery
41
1F-41
Purge control valve short circuit to ground or open
44
1F-62
Cooling fan (HI) relay short circuit to power
45
1F-62
Cooling fan (HI) relay short circuit to ground or open
54
1F-41
Purge control circuit malfunction
56
1F-23
No.1 knock sensor signal failure
57
1F-23
No.2 knock sensor signal failure
58
1F-17
Camshaft position sensor signal: No.1 cylinder synchronization failure
59
1F-78
CAN communication failure: MSR data transmission not plausible
60
1F-78
CAN communication failure: ASR data transmission not plausible
62
1F-61
Clutch switch defective
64
1F-11
No ignition voltage output (No.1 ignition coil)
65
1F-11
66
1F-11
67
1F-13
Crankshaft position sensor adaptation failure
68
1F-25
Random/Multiple Misfire
71
1F-29
Starter signal recognition failure
72
1F-37
No.1 injector short circuit to battery
73
1F-37
No.1 injector short circuit to ground or open
74
1F-37
75
1F-37
76
1F1-37
77
1F-38
78
1F-38
79
1F-38
80
1F-72
Oxygen sensor high voltage
81
1F-73
Bank 1 system short term fuel trim adaptation below lean threshold
82
1F-72
Oxygen sensor no activity detected
83
1F-72
Oxygen sensor not lean after overrun fuel shut -off
84
1F-72
Oxygen sensor slow response
85
1F-72
Oxygen sensor heater failure
86
1F-72
Oxygen sensor heater short circuit to battery
87
1F-72
Oxygen sensor heater short circuit to ground or open
89
1F-72
Oxygen sensor low voltage
93
1F-73
Bank 1 system short term fuel trim adaptation above rich threshold
96
1F-73
Bank 1 system short term fuel trim at rich stop
97
1F-73
Bank 1 system short term fuel trim at lean stop
98
1F-73
Bank 1 system idle adaptation failure (above rich threshold)
99
1F-73
Bank 1 system idle adaptation failure (below lean threshold)
100
1F-73
Bank 1 system learning control failure (rich, low load)
101
1F-73
Bank 1 system learning control failure (lean, low load)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-6

Description
102
1F-73
Bank 1 system learning control failure (rich, high load)
103
1F-73
Bank 1 system learning control failure (lean, high load)
104
1F-47
Throttle position sensor 1 low voltage
105
1F-47
Throttle position sensor 1 high voltage
108
1F-47
Throttle position sensor 2 low voltage
109
1F-47
Throttle position sensor 2 high voltage
110
1F-80
Throttle actuator learning data fault
116
1F-47
Throttle actuator learning control failure
117
1F-80
Exceed fuel -cut safety time
119
1F-47
Throttle valve return spring failure
120
1F-80
Cruise control interruption memory failure
121
1F-47
Throttle actuator failure
122
1F-59
Accelerator pedal position sensor signal failure
123
1F-47
Different Mass air flow sensor signal with throttle position sensor
125
1F-47
Both throttle position sensors failure
126
1F-48
Throttle position sensor 1 not plausible with throttle position sensor 2
127
1F-48
High permanent throttle signal
129
1F-64
Cruise control OFF due to message counter failure
130
1F-64
Vehicle speed signal failure
131
1F-64
Vehicle speed signal failure
132
1F-64
Cruise control lever failure
133
1F-64
Cruise control acceleration failure
134
1F-64
Cruise control deceleration failure
135
1F-67
Stop lamp switch failure
136
1F-79
ECU failure (RAM)
137
1F-79
ECU failure (EPROM)
138
1F-80
Call monitoring
139
1F-80
Servo motor control output interruption memory failure
140
1F-80
Servo motor open/short
141
1F-82
Unprogramed ECU with immobilizer
142
1F-79
Uncoded/unprogramed ECU
143
1F-79
ECU failure (EEPROM/Flash-EPROM checksum failure)
144
1F-79
ECU failure (coding ID checksum failure)
145
1F-79
ECU failure (coding checksum failure)
146
1F-79
ECU failure (programing checksum failure)
150
1F-65
TCS input signal short circuit to battery
151
1F-65
TCS input signal short circuit to ground or open
160
1F-59
Accelerator pedal position sensor 1 low voltage
161
1F-59
Accelerator pedal position sensor 1 high voltage
162
1F-59
Accelerator pedal position sensor 2 low voltage
163
1F-59
Accelerator pedal position sensor 2 high voltage
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-7

Description
164
1F-59
Accelerator pedal position sensor 1 not plausible with pedal position sensor 2
167
1F-59
Both setpoint accelerator pedal position sensor defective
185
1F-48
Mass air flow sensor and throttle position sensor failure
186
1F-80
ECU failure (incompatible CPU)
187
1F-80
ECU failure (CPUs communication failure)
188
1F-80
ECU failure (CPU 2 configuration failure)
189
1F-80
ECU failure (CPU 2 fault)
190
1F-80
ECU failure (CPU run time failure between CPUs)
192
1F-38
193
1F-38
194
1F-38
195
1F-38
198
1F-66
Resonance flap short circuit to battery
199
1F-66
Resonance flap short circuit to ground or open
226
1F-21
Camshaft actuator short circuit to battery
227
1F-21
Camshaft actuator short circuit to ground or open
228
1F-63
A/C compressor relay short circuit to battery
229
1F-63
A/C compressor relay short circuit to ground or open
231
1F-80
ECU failure (CPU 2 cruise control message counter failure)
232
1F-80
Over decceleration limit (CPU 2)
233
1F-80
Over acceleration limit (CPU 2)
234
1F-80
Cruise control lever dual operation (CPU 2)
235
1F-80
Cruise control lever safety terminal failure (CPU 2)
236
1F-80
Unusual pedal position variation (CPU 2)
237
1F-80
Unusual throttle position variation (CPU 2)
238
1F-80
Unusual throttle controller monitor data comparison fault (CPU 2)
239
1F-81
Unusual accelerator pedal position sensor comparison fault (CPU 2)
240
1F1-81
Throttle potentiometer comparision fault (CPU 2)
241
1F-81
Unusual CPU communication (CPU 2)
242
1F-81
Unusual CPU configuration (CPU 2)
243
1F-81
A/D converter failure (CPU 2)
244
1F-81
Accelerator pedal position sensor setpoint fault between CPU 1 and CPU 2
245
1F-81
Position controller setpoint fault between CPU 1 and CPU 2
246
1F-81
MSR setpoint fault between CPU 1 and CPU 2
247
1F-81
Idle control setpoint fault between CPU 1 and CPU 2
248
1F-81
A/D converteroverflow (CPU 2)
249
1F-81
ROM f aul t (CPU 2)
250
1F-81
RAM f aul t (CPU 2)
251
1F-85
Cycle monitor fault (CPU 2)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-8
IGNITION SYSTEM
This ignition system does not use a conventional distributor and coil. It uses a crankshaft position sensor input to the Engine Control Module (ECM). The ECM then
determines Electronic Spark Timing (EST) and triggers
the electronic ignition system ignition coil.
This type of distributorless ignition system uses a waste
spark method of spark distribution. Each cylinder is paired
with the cylinder that is opposite it (1-6 or 2-5 or 3-4). The
spark occurs simultaneously in the cylinder coming upon
the compression stroke and in the cylinder coming up on
the exhaust stroke. The cylinder on the exhaust stroke
requires very little of the available energy tofire the spark
plug. The remaining energy is available to the spark plug
in the cylinder on the compression stroke.
CHANGED BY
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These systems use the EST signal from the ECM to control the EST. The ECM uses the following information:
Engine load (mass air flow sensor).
Engine temperature.
Intake air temperature.
Crankshaft position.
Engine speed (rpm).
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-9
IGNITION COIL
1. Control cable connection

2. Ignition cable
5a, 5b. Secondary voltage connection

E. Iron core
3. Spark plug connector
L1. Secondary ignition coil
4. Coupling plug
L2. Primary ignition coil
The Electronic Ignition (EI) system ignition coil is located on the cylinder head cover. The double ended coils receive the
signal for the Engine Control Module (ECM) which controls the spark advance.
Each EI system ignition coil provides the high voltage to two spark plugs simultaneously;
T1/1: cylinder 2 and 5
The EI system ignition coil is not serviceable and must be replaced as an assembly.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-10
Failure Code
Description
64
No ignition voltage
output
(No. 1 ignition coil)
Trouble Area
Maintenance Hint
Inspection the ECM pin 70 (71 and 72)
about short circuit or open with bad
contact
Inspection the power source to ignition
65
No ignition voltage
output
66
No ignition voltage
output
Malfunction of ignition
circuit Primary current
values or secondary
short circuit
Inspection the power source to ignition coil

Inspection the ignition coil, high tension
cords etc.
Inspection the spark plug (wet, cracks,
wear, improper gap, burned electrodes,
heavy deposit)
Inspection the ECM
Circuit Description
The Electronic Ignition (EI) system uses a waste spark method of spark distribution. The Crankshaft Position (CKP)
sensor sends reference pulses to the ECM. The ECM then triggers the EI system ignition coils. Once the ECM triggers
the EI system ignition coils both of the connected spark plugs fire at the same time. One cylinder is on its compression
stroke at the same time that the other is on the exhaust stroke, resulting in lower energy needed to fire the spark plugin
the cylinder on its exhaust stroke.
This leaves there remainder of the high voltage to be used to fire the spark plug in the cylinder on its compression stroke.
Since the CKP sensor is in a fixed position, timing adjustments are not possible or needed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-11
CRANKSHAFT POSITION (CKP) SENSOR
1. Crankshaft position sensor
3. Segment
2. Bolt
4. Flywheel
This Electronic Ignition (EI) system uses inductive or pick up type magnetic Crankshaft Position (CKP) sensor. The
CKP sensor is located in the opposite side of the crankshaft pulley and triggers the pick-up wheel teeth which is
equipped 60 - 2 teeth with a gap of 2 teeth at 360 degree spacing. This sensor protrudes throughits mount to within 1.1
0.14 mm.
The output of the sensor is a sinusoidal signal. Each tooth of the pick-up 60 - 2 wheel generates a positive half wave.
The Engine Control Module (ECM) uses this sensor signal to generate timed ignition and injection pulses that it sends
to the ignition coils and to the fuel injectors.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-12
Failur Code
Description
Trouble Area
Maintenance Hint
17
Crankshaft position
sensor signal failure (no
engine revolution signal)
Even through cam position

recognition is normal, no crankshaft position signal recognition
Monitoring the actual rpm through

or scan tool
18
Crankshaft position
sensor signal failure
(rpm > max. value)
When more than applicable

revolution values or implausible
to 60-2 teeth scan tool
Crankshaft position
sensor signal failure
(gap recognition failure)
When implausible recognition of

cam and crank angle signal or
intermittent sensing the signal or
error count of undetected gap.
Crankshaft position
sensor adaptation failure
When faulty crank angle

sensor adaption
20
67
Inspection the ECM pin 100, 99

about short circuit with bad
contact
Inspection the CKP sensor
Inspection the air gap between
sensor and drive plate
Inspection the drive plate (teeth
condition)
Inspection the ECM
Circuit Description
The 58X reference signal is produced by the CKP sensor. During one crankshaft revolution, 58 crankshaft pulses will be
produced. The ECM uses the 58X reference signal to calculate engine rpm and CKP. The ECM constantly monitors the
number of pulses on the 58X reference circuit and compares them to the number of Camshaft Position (CMP) signal pulses
being received. If the ECM receives and incorrect number of pulses on the 58X reference circuit, this failure code will set.
Crankshaft Position Sensor Resistance Inspection

1. Disconnect the coupling E of ECM while the ignition switch is in OFF position.
2. Measure the resistance between the coupling terminal pin No. 99 and No. 100 using a multimeter.
Specified value
1,050 ~ 1,400
Notice
Measure the insulator resistance of the CKP sensor if out of the specified value.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-13
Crankshaft Position Sensor Output

Wave Inspection
1. Measure the output wave between the ECM terminals
No. 99 and No. 100 using the scan tool or the oscilloscope
while engine cranking (start motor activated).
Notice
Check the segment or crankshaft position sensor and
air gap if cannot get the output wave as shown in the
figure.
Crankshaft Position Sensor

Insulator Resistance Inspection
1. Disconnect the coupling from ECM while the ignition
switch is in OFF position.
2. Measure the resistance between the coupling terminal
pin No. 100 and No. 69 using a multimeter.
Specified value
>20 k
Notice
Measure the check and ground terminal of the CKP
sensor if out of the specified value.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-14
CAMSHAFT POSITION (CMP) SENSOR
1. Camshaft position sensor connector
3. Camshaft position sensor
2. Bolt
4. O-ring
The Camshaft Position (CMP) sensor sends a CMP signal to the Engine Control Module (ECM). The ECM uses this
signal as a synchronized pulse to trigger the injectors in the proper sequence. The ECM uses the CMP signal to
indicate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel
injection mode of operation.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-15
Failur Code
Description
Trouble Area
19
Camshaft position
sensor signal : No. 1
cylinder recognition
failure
When no cam recognition signal

during TN 24 counts more.
(maintain the constant low or
high level)
58
Camshaft position
sensor signal : No. 1
cylinder synchronization failure
When synchronization fault of

cylinder 1
(TDC recognition)
Maintenance Hint
Inspection the source voltage of
CMP sensor
about short circuit or open with
bad contact
Inspection the CMP sensor
Inspection the damage of sensor
or sprocket
Inspection the ECM
Circuit Description
The CMP sensor sends a cam position signal to the ECM. If the cam position signal is lost while the engine is running,
the fuel injection system shifts to a calculated sequential fuel injection mode based on the last fuel injection pulse, and
the engine continuous to run.
Camshaft Position Sensor Signal Voltage Inspection

1. Measure the voltage between the ECM terminal No. 11 and No. 106 while the engine speed is at idle.
Specified value
1.2 ~ 1.7V
Notice
The signal voltage will be changed in the range of 1.2 ~ 1.7V.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-16
Camshaft Position Sensor Output

Wave Inspection
1. Measure the output wave between the ECM terminals
No. 104 and No. 106 using the scan tool or the
oscilloscope while engine speed is at idle.
Notice
Replace the CAM sensor if cannot get the out-put
wave as shown in the figure.
Camshaft Position Sensor Power

Supply Inspection
1. Disconnect the CMP sensor Connector.
2. Measure the voltage between the No. 1and No. 3 pin of
the CMP sensor connector while the ignition switch is in
ON position.
Specified value
11 ~ 14V
Notice
If the measured value is not within the specified value,
check the cable.
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-18
CAMSHAFT ACTUATOR
1. Bolt
4. Armature
2. Camshaft actuator
5. Roll pin
3. Bolt
6. Nut
When the engine is running, the camshaft actuator rotates the intake camshaft hydraulically and mechanically relative
to the camshaft sprocket by 32 crank angle to the advanced position and back to the retard position.
The camshaft actuator is actuated electro-mechanically by the Engine Control Module (ECM).
The positioning time of apporx. 1 second is dependent on the engine oil pressure at the camshaft actuator and on the oil
viscosity and oil temperature, respectively.
The camshaft indicator on the camshaft sprocket provides the camshaft rotational speed to the position sensor as an
input parameter for the engine ignition control unit.
Operation Condition of Camshaft Actuator

Engine RPM
Camshaft Position
Effect
Engine stop
Retard
Idle speed is improved
0 ~ 1,500 rpm
Retard
Blow-by gas is decreased

Valve overlap is decreased
Torque is increased
1,500 ~ 4,300 rpm
Advanced
Fuel loss is decreased

NOx is decreased
Above 4,300 rpm
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AFFECTED VIN
Retard
Engine overrun is prohibited
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-19
Failur Code
Description
Trouble Area
Monitoring the actual operational

status through scan tool
Camshaft actuator short

circuit to battery
226
Inspection the ECM pin 73 about

short circuit or open
When malfunction of cam
phasing control
Camshaft actuator
short circuit to ground
or open
227
Maintenance Hint
Inspection the power source short

circuit or open to cam actuator
Inspection the magnet and
hardware
Inspection the ECM
Camshaft Actuator Current Consumption Inspection

1. Run the engine to reach the coolant temperature above 70 C.
2. Increase the engine rpm up to 2000 rpm
3. Measure the current between the No. 1 and No. 2 pin of the camshaft actuator connector.
Specified value
1 ~ 1.5 A
Notice
If the measured value is not within the specified value, check the cable.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-20
KNOCK SENSOR (KS)
The Knock Sensor (KS) detects abnormal knocking in the engine. The two KS are mounted in the engine block near the
cylinders. The sensors produce an output voltage which increases with the severity of the knock. This signal is sent to
the Engine Control Module (ECM) via a shielded cable. The ECM then adjusts the ignition timing to reduce the spark
knock.
CHANGED BY
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ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-21
Failur Code
56
Description
Trouble Area
Maintenance Hint
No. 1 knock sensor

signal failure
When recognition in more than

control gain threshold at normal
operational condition of other
system during over 75 and 3,000 rpm
running area (cylinder 1, 2, 3)
Inspection the ECM pin 118,

117about short circuit or open with
bad contact
When recognition in more than

control gain threshold at normal
operational condition of other
system during over 75 and 3,000 rpm
running area (cylinder 4, 5, 6)

bad contact
No. 2 knock sensor

signal failure
57
Inspection the KS 1 malfunction

Inspection the ECM
Inspection the KS 2 malfunction

Inspection the ECM
Circuit Description
The KS system is used to detect engine detonation, allowing the ECM to retard the ignition control spark timing based
on the KS signal being received. The KS signals amplitude and frequency depend upon the amount of knock being
experienced. The ECM monitors the KS signal and can diagnose the KS sensor and circuitry.
Knock Sensor Resistance Inspection

1. Disconnect the coupling from ECM while the ignition switch is in OFF position.
2. Measure the resistance between the coupling terminal pin No. 118 and No. 117 and terminal pin No. 115 and No.
114 using a multimeter.
Specified value
>10 M
Notice
Replace the KS if the measured values is out of the specified values. Check the connector and wire connection
between ECM and the KS if the measured values are normal.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-22
SPARK PLUG
1. Ignition coil cable cover
T 1/1 Ignition Coil ............................... Cylinder 2 and 5
2. Bolt
3. Spark plug
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-23
Failur Code
Description
Random / Multiple
Misfire
68
Trouble Area
When detection misfire of

multiple cylinder for source of
over the emission threshold
or catalyst damage
Maintenance Hint
Inspection the ignition system

Inspection the injection system
Inspection the fuel pressure
Inspection the compression pressure
Inspection the valve timing or clearance
Inspection the air flow sensor
Inspection the crankshaft position
sensor and air gap
Inspection the engine wiring system
Inspection the Engine Control Module
(ECM)
Circuit Description
The ECM monitors the crankshaft and camshaft positions to detect if the engine is misfiring. The ECM looks for a quick
drop in crankshaft speed. Misfire multiple cylinder is monitored by engine roughness measuring. The actual roughness
value is compared with the actual (emission and catalyst damage) threshold.
Spark Plug Cable Resistance Inspection

1. Turn the ignition switch OFF position.
2. Disconnect the spark plug cables Refer to Section 1E1, Engine electrical.
3. Measure the spark plug resistance using a multimeter.
Specified value
1.8 ~ 2.2 k
Notice: Replace the spark plug cable if the measured values is out of the specified values.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-24
SYSTEM VOLTAGE
Failur Code
Description
Trouble Area
Maintenance Hint
Monitoring the actual battery
voltages through the scan tool
08
System voltage too low
Malfunction in recognition of
system source voltage. Less
than minimum 8 volts in
2,000 rpm below, or less than 10
volts in 2,000 rpm above.
Inspection the Engine Control

Module (ECM) pin 12, 11, 10, 5
bad contact
Inspection the over voltage
protection relay
Inspection the battery
Inspection ECM
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-25
IGNITION SWITCH
Failur Code
Description
Trouble Area
71
Starter signal
recognition failure
When not detection of starter

signal
Maintenance Hint
Module (ECM) pin 2 circuit short
or open with bad contact
Inspection ECM
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-26
FUEL SYSTEM
The function of the fuel metering system is to deliver the correct
amount of fuel to the engine under all operating conditions.
The fuel is delivered to the engine by the individual fuel injectors mounted into the intake manifold near each cylinder.
The main fuel control sensors are the Mass Air Flow (MAF)
sensor and the oxygen (O2) sensors.
The MAF sensor monitors the mass flow of the air being
drawn into the engine. An electrically heated element is
mounted in the intake air stream, where it is cooled by the
flow of incoming air. Engine Control Module (ECM) modulates the flow of heating current to maintain the temperature
differential between the heated film and the intake air at a
constant level. The amount of heating current required to
maintain the temperature thus provides an index for the mass
air flow. This concept automatically compensates for variations in air density, as this is one of the factors that determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located between the air filter and the throttle valve.
Under high fuel demands, the MAF sensor reads a high
mass flow condition, such as wide open throttle. The ECM
uses this information to enrich the mixture, thus increasing the fuel injector ontime, to provide the correct amount
of fuel. When decelerating, the mass flow decreases. This
mass flow change is sensed by the MAF sensor and
read by the ECM, which then decreases the fuel injector
ontime due to the low fuel demand conditions.
The O2 sensors are located in the exhaust pipe before
catalytic converter. The O2 sensors indicate to the ECM
the amount of oxygen in the exhaust gas, and the ECM
changes the air/fuel ratio to the engine by controlling the
fuel injectors. The best air/fuel ratio to minimize exhaust
emissions is 14.7 to 1, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the
fuel injection system is called a closed loop system.
The ECM uses voltage inputs from several sensors to determine how much fuel to provide to the engine. The fuel is
delivered under one of several conditions, called modes.
Starting Mode
When the ignition is turned ON, the ECM turns the fuel
pump relay on for 1 second. The fuel pump then builds
fuel pressure. The ECM also checks the Engine Coolant
Temperature (ECT) sensor and the Throttle Position (TP)
sensor and determines the proper air/fuel ratio for starting the engine. This ranges from1.5 to 1 at
-36C (-33F) coolant temperature to 14.7 to 1 at
94C (201F) coolant temperature. The ECM controls the
amount of fuel delivered in the starting mode by changing
how long the fuel injector is turned on and off. This is
done by pulsing the fuel injectors for very short times.
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Run Mode
The run mode has two conditions called open loop and
closed loop.
Open Loop
When the engine is first started and it is above 690 rpm,
the system goes into open loop operation. In open loop,
the ECM ignores the signal from the O2S and calculates
the air/fuel ratio based on inputs from the ECT sensor
and the MAF sensor. The ECM stays in open loop until
the following conditions are met:
The O2 has a varying voltage output, showing that it
is hot enough to operate properly.
The ECT sensor is above a specified temperature (22.
5C).
A specific amount of time has elapsed after starting
the engine.
Closed Loop
The specific values for the above conditions vary with different engines and are stored in the Electronically Erasable programmable Read-Only Memory (EEPROM).
When these conditions are met, the system goes into
closed loop operation. In closed loop, the ECM calculates the air/fuel ratio (fuel injector on-time) based on the
signals from the O2 sensors. This allows the air/fuel ratio
to stay very close to 14.7 to 1.
Acceleration Mode
The ECM responds to rapid changes in throttle position
and airflow and provides extra fuel.
Deceleration Mode
The ECM responds to changes in throttle position and
airflow and reduces the amount of fuel. When deceleration is very fast, the ECM can cut off fuel completely for
short periods of time.
Battery Voltage Correction Mode
When battery voltage is low, the ECM can compensate
for a weak spark delivered by the ignition module by using the following methods:
Increasing the fuel injector pulse width.
Increasing the idle speed rpm.
Increasing the ignition dwell time.
Fuel Cut-Off Mode
No fuel is delivered by the fuel injectors when the ignition
is off. This prevents dieseling or engine run-on. Also, the
fuel is not delivered if there are no reference pulses received from the CKP sensor. This prevents flooding.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-27
FUEL PUMP
1. Flange and harness assembly
5. Thermistor
2. Spring
6. Float arm
3. Fuel pump
7. Thermistor housing
4. Float
8. Resistor card and wiper
Requirements for Fuel Pump

Item
System pressure
Specified Value
3.8 bar
Item
Minimum delivery at 8v
Maximum pressure
8.5 bar (12 V)
Operating voltage
Minimum pressure
5.0 bar (12 V)
Maximum allowable current
Nominal voltage
Minimum amount of fuel
supply
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
12 V
114 Liter/Hr (12 V, 3.8 bar,
-30 ~ +70 C)
Ambient temperature
Maximum amount of fuel
supply
Specified Value
30 Litre/Hr
8V
7.5 A
-30 ~ +70 C
165 Liter/Hr (12V, 3.8 bar,
-30 ~ +70 C)
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AFFECTED VIN
1F-28
Failur Code
Description
Trouble Area
34
Fuel pump relay

short circuit to battery
When short circuit to power

source
35
Fuel pump relay

or open
When short circuit to ground or

open open with bad contact
Maintenance Hint
Module (ECM) pin 33 about short
circuit or open with bad contact
Inspection the fuel pump relay
Inspection the ECM
Circuit Description
When the ignition switch is turned ON, the ECM will activate the pump relay and run the in-tank fuel pump. The fuel
pump will operate as long as the engine is cranking or running and the ECMis receiving ignition reference pulses.
If there are no reference pulses, the ECM will shut off the fuel pump within 2 seconds after the ignition switch is turned
ON, engine stopped or engine stalled.
Fuel Pump Relay Inspection

Measure the voltage between the ECM terminal No. 33 and ground.
Ignition Switch: ON
0 V (for1 ~ 2 sec.)
Cranking
0V
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-29
Measure the Fuel Delivery from the Fuel Pump

1. Disconnect the return pipe from fuel distributor and insert the appropriate hose into it.
2. Place the hose end into the beaker with the minimum capacity of 1 Liter
3. Turn the ignition switch to ON position.
4. Connect the terminal No. 33 and No. 5 of ECM with a service wire.
5. Measure the fuel delivery from the fuel pump
Specified value
1 Liter/max. 35 sec.
Notice
Check the fuel filter and fuel line when the fuel delivery is not within specified value.
Measure the Current Consumption of Fuel Pump

1. Remove the fuel pump relay from fuse and relay box in trunk, and turn the ignition switch to ON position.
2. Using a multimeter, measure the current consumption by connecting the terminal No. 30 and No. 87 of the fuel
pump relay connector.
Specified value
5~9A
Notice
Replace the fuel pump relay if the measured value is over 9 A.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-30
FUEL INJECTOR
1. Fuel rail
4. Injector
2. O-ring
5. O-ring
3. Injector bracket
The Multipoint Fuel Injection (MFI) assembly is a solenoid-operated device controlled by the Engine Control Module
(ECM) that meters pressurized fuel to an each individual cylinder. The injector sprays the fuel, in precise quantities at
a point in time determined by the ECM, directly to ward the cylinder intake valve. ECM energizes the fuel injector
solenoid to lift the needle valve and to flow the fuel through the orifice. This injectors discharge orifice is calibrated to
meet the effective fuel atomization necessary for both ensuring the maximum homogeneity in the air-fuel mixture and
holding the condensation along the walls of the intake tract to a minimum.
Fuel enters the top feed injector from above and flows through its vertical axis. The lower end extends into the intake
valve. Fuel from the tip is directed at the intake valve, causing it to become further atomized and vaporized before
entering the combustion chamber.
A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engineis shut down. Also, an
extended crank time would be noticed on some engines. Dieseling could also occur because some fuel could be
delivered to the engine after the ignition is turned off.
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ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-31
Failur Code
Description
72
No. 1 injector short

circuit to battery
Trouble Area
When malfunction of injector
circuit
Injector #1 short circuit to power
73
74

circuit to ground or
open

circuit to battery

circuit
Injector #1 short circuit to
ground or open
circuit
75
76

open

circuit to battery

circuit
ground or open
circuit
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Maintenance Hint
Inspection the power to injector #1
or bad contact
Inspection the injector
Inspection the ECM
short circuit or open with bad contact
Inspection the ECM
or bad contact
Inspection the ECM
Inspection the ECM
or bad contact
Inspection the ECM
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AFFECTED VIN
1F-32
Failur Code
Description
77

open
78
79
192
193
194
195
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circuit to battery

open

circuit to battery

open

circuit to battery

open
Trouble Area
Maintenance Hint

circuit


ground or open
circuit
circuit
ground or open
circuit
circuit
ground or open
circuit
circuit
ground or open

Inspection the ECM
or bad contact
Inspection the ECM
Inspection the ECM
or bad contact
Inspection the ECM
Inspection the ECM
or bad contact
Inspection the ECM
Inspection the ECM
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-33
Injector Spray Pattern Check

1. Turn the ignition switch OFF.
2. Remove the fuel injector connectors.
3. Remove the fuel distributor and injector with a unit. At
this time, do not remove the supply and return line.
Notice
Prepare the beaker for taking the fuel.
4. Connect the shop made cable to the injector with a firing
order.
5. Connect the other end of shop made cable to the positive
battery cable and negative battery cable.
6. Turn the ignition switch ON.
7. Check the injector for normal spray pattern as shown in
the figure. Check injector for leaks or later drop
Injector Resistance Inspection

2. Remove the fuel injector connectors.
3. Measure the fuel injector coil resistance using a
multimeter.
Specified value
14 ~ 17
Notice
Replace the fuel injector if the measured value is out
of the specified values. Check the connector and wire
connection between the ECM and the injector if the
measured values are normal.
Injector Pulse Width Inspection

2. Install the scan tool.
3. Turn the ignition switch ON.
4. Monitor the INJECTION TIME with a scan tool.
Cranking
8.0 ms
Engine Idle
3 ~ 5 ms
Wide Open Throttle (WOT)
14 ms
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-34
PURGE CONTROL VALVE
1. Purge control valve
3. Line to conister
2. Line to engine
The fuel vaporization control system is in stalled to inhibit the fuel vaporized gas from discharging into the atmosphere.
The fuel vaporized gas that is accumulated in the canister abstracts through the purge control valve purification during
the engine combustion (except the decreasing mode) and coolant temperature of over 80C. For this reason, the Engine
Control Module (ECM) transacts the engine speed, air inflow quantity, coolant temperature, and intake temperature.
The purge control valve is activated by the ECM frequency according with the engine rotating speed to adjust the
purification rate. The purification rate is determined by the continuous valve opening interval.
The purge control valve is activated by the ECM for the following conditions:
Coolant temperature of over 80C
Engine speed of over 1,000 rpm
2 minutes after starting
When the fuel cut-off mode is not activated
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ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-35
Failur Code
Description
Trouble Area
40
Purge control valve

When short circuit to power

source
41
Purge control valve

or open
When short circuit to ground or

open circuit or open with bad
contact
Purge control circuit

malfunction
When malfunction of purge

control: not work vale
54
Maintenance Hint
short circuit or open with bad
contact.
Inspection the source power of
valve
Inspection the purge control
solenoid vale
Inspection the ECM
Test
1. Maintain the normal temperature and idling state by
operating the engine.
2. Connect the ECM terminal No. 11 and No. 34 and check
for normal operation through the output waves using
oscilloscope.
Notice
Test during purge control valve operation after the
minimum of 1 minute after the engine turned on.
3. Connect the ECM terminal No. 34 and No.10 and check
for current consumption during the ignition switch ON.
Specified value
0.3 ~ 0.5 A
4. Remove the line to canister and measure the pressure

with the vacuum pressure gauge.
Specified value
> 500 mbar

(after approx. 1 min.)
purge control valve operates at this time
Notice
Test while at normal temperature and at idling state
by operating the engine.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-36
FUEL RAIL
1. Injector connector
5. Fuel return line
2. Injector
6. Bolt
3. Fuel rail
7. Vacuum hose
4. Fuel supply line
8. O-ring
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-37
Fuel Pressure Test

Tools Required
A9922 0012A (103 589 00 21 00)
Fuel Pressure Gauge
1. Turn the ignition switch to OFF position.

2. Remove the fuel pressure test connector.
3. Connect the fuel pressure gauge to the fuel pressure
test connector.
4. Test the fuel pressure at idling by operating the engine
using the fuel pressure gauge A9922 0012A (103 589
00 21 00).
Vacuum hose connected (bar)
3.2 ~ 3.6
Vacuum hose disconnected (bar)
3.7 ~ 4.2
5. Replace the pressure regulator diaphragm if out of the

specification.
Internal Leakage Test

1. Connect thefuel pressure gauge A9922 0012A (103 589
00 21 00) to the fuel pressure test connector.
2. Stop the engine for approximately 30 minutes and then
check the fuel pressure changes.
Pressure Change
Fuel pressure drops
slowly
Fuel leakage at the

injector
Faulty fuel pressure
regulators
diaphragm and O-ring
Fuel pressure drops

rapidly
Faulty check valve in

the fuel pump
3. If there is no change in fuel pressure and maintain the

following pressure over 30 minutes, it is normal.
Fuel pressure (bar)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-38
FUEL PRESSURE REGULATOR
1. Vacuum hose
4. O-ring
2. Circlip
5. O-ring
3. Fuel pressure regulator
Function of the Fuel Pressure Regulator

The fuel pressure regulator maintains the fuel pressure in the
fuel line with the pressure of 3.2 bars to 3.8 bars according to
the intake manifold pressure. This operating pressure cannot
be changed, and the fuel injection volume will be only determined by the injection time.
Over supplied fuel returns to the fuel tank through the return line.
<Operating at full load>
There is no negative pressure applied to the spring chamber
(9) during the full load, and it is separated from the fuel chamber (8) by the diaphragm (5).
2. Fuel return line
8. Fuel chamber
3. Valve
9. Spring chamber
5. Diaphragm
A. Valves closed
B. Valves opened
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AFFECTED VIN
When the fuel pressure goes up, the diaphragm forces the
compression spring (6) in the direction of compression. At
this moment, the valve (3) sticks to the diaphragm by the fuel
pressure, and the fuel return line (2) opens. The fuel over supplied returns to the fuel tank through the return line.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-39
The pressure difference between the fuel pressure and
the intake manifold is about 3.8 bars during the full load.

2. Intake manifold
3. Fuel return (to fuel tank)
2. Intake manifold
4. Fuel supply (from fuel pump)
3. Fuel return (to fuel tank)
7. Fuel pressure (approx. 3.2 bars)
4. Fuel supply (from fuel pump)
8. Intake manifold negative pressure (0.6 bars)
5. Fuel paressure (approx. 3.8 bars)
<Fuel Pressure Diagram>
6. Intake manifold negative pressure (0 bar)
<Operating at Idle and partial load>

The spring chamber (9) is connected to the intake manifold with the vacuum hose at the intake pipe connection
(7). The negative pressure generated in the intake manifold activates the diaphragm, and thus the fuel pressure
gets reduced to the rate of the operating extent of the
diaphragm by the intake manifolds negative pressure.
A. Fuel pressure
B. Intake manifold negative pressure
LL. Idling
TL. Partial load
VL. Full load
Consequently, the fuel pressure in the fuel distributor

changes by the intake manifolds negative pressure, and
the injectors fuel pressure gets reduced independently
to the throttle valves position. Thus, the fuel injection
volume can only be determined according to the injectors
injecting duration.
The pressure difference between the fuel pressure and
the intake manifold is approx. 3.2 bars during idling.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-40
INDUCTION SYSTEM
THROTTLE VALVE ACTUATOR
The throttle actuator is actuated by the Engine Control

Module(ECM) according to the position of the accelerator pedal position.
It has two potentiometers which signal the position of the
throttle valve to the ECM to enable it to recognize the
various engine load states.
Ignition OFF
In the de-energized states the throttle valve position is
determined to be spring capsule.
Ignition ON
When the ignition S/W on the servo motor in the throttle
actuator is operated by the ECM. The throttle valve adopts
a position in line with the coolant temperature.
Closed Position
In the closed throttle position, the servo motor controls
engine speed by operating the throttle valve further (greater
mixture) or closing it further (reduced mixture), depending on coolant temperature and engine load. When this is
done, the throttle valve can be closed further by the servo
motor overcoming the force of the spring capsule (mechanical end stop). If the actuator is deenergized, the
throttle valve is resting against the spring capsule.
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AFFECTED VIN
Consequently, the throttle valve opening is a constant 10

~ 12 approximately.
At no load, this produces an engine speed of about 1,800 rpm
Driving
When driving (part/full throttle), the servo motor controls
the throttle valve in line with the various load states and
according to the input signals from the pedal value sensor according to the input signals from the pedal value
sensor according to the position of the accelerator pedal.
The function of the EA (electronic accelerator) in the ECM
determines the opening angle of the throttle valve through
the throttle actuator. Further functions are;
Idle speed control
Cruise control
Reducing engine torque for ASR/ABS operation
Electronic accelerator emergency running
Storing faults
Data transfer through CAN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-41
Failur Code
Description
Trouble Area
104
Throttle position sensor

1 low voltage
TPS 1 short circuit to ground or

open
105

1 high voltage
TPS 1 short circuit to power
108

2 low voltage
TPS 2 short circuit to ground or

open
109

2 high voltage
TPS 2 short circuit to power
116
Throttle actuator
learning control failure
When actuator adaption fluctuation or not meet the condition

scan tool
Inspection the ECM pin 84, 85,

87, 112, 67, 68 about short circuit
119
Throttle valve return

spring failure
When return spring defective of

actuator with bad contact
Inspection the throttle valve

actuator
121
Throttle actuator failure
When supply voltage of the

actuator short circuit to power
Inspection the ECM
Inspection the ECM
123
Different mass air flow

sensor signal with
throttle position sensor
When shut down of output driver
125
Both throttle position

sensor failure
When defective of both potentiometers
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Maintenance Hint
Monitoring the actual values

through
CHANGED BY
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AFFECTED VIN
1F-42
Failur Code
Description
Trouble Area
126

1 not plausible with
Throttle position sensor 2
Maintenance Hint
When difference between TPS 1

and TPS 2
127
High permanent throttle

signal
When failure of wiring harness or

actuator
185
Mass air flow sensor

and throttle position
sensor failure
When difference between MAF

and TPS signal

through scan tool
Inspection the throttle valve
actuator
Inspection the ECM
Circuit Description
The ECM supplies a 5 volt reference signal and a ground to the TP sensor. The TP sensor sends a voltage signal back
to the ECM relative to the throttle plate opening. The voltage signal will vary from approximately 0.3 ~ 0.9 volts at closed
throttle, to over 4.0 ~ 4.6 volts at Wide Open Throttle (WOT).
The TP sensors serve for engine load control according to the drive pedal command. Load adjustments independent of
the drive pedal command can be implemented; such functions are, for instance, idle control, speed control, drive slip
control, load shock damping, and similar functions.
When the actuator current fails, the throttle valve is returned to emergency operating position by a spring. The throttle
valve position, thereby the actuator drive position check back is provided by two potentiometers. The motor positions the
throttle valve against the return spring force. Motor and return spring are two separate energy sources. Each of Them is
able to position the throttle valve in emergency position alone. Throttle valve position check back and monitoring is
provided by two actual value potentiometers connected to the engine control electronics.
Throttle Actuator Inspection

2. Measure the TPS 1 signal voltage at the ECM pin No.
87 and TPS 2 signal voltage at the ECM pin No. 85.
TPS 1
TPS 2
Pedal Position
Specified Value
Closed
0.3 ~ 0.9V
Opened
1 4.0 ~ 4.6V
Closed
4.0 ~ 4.6V
Opened
0.3 ~ 0.9V
Throttle Actuator DC Motor

Resistance
2. Measure the resistance between the ECM pin No.
67 and No. 68.
Specified value
<10
Throttle Actuator DC Motor

Inspection
2. Measure the signal voltage between the ECM pin
No. 67 and No. 68.
Application
Engine
status
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AFFECTED VIN
Specified Value
Ignition ON
0.8 ~ 2.3 v
Idling
1.0 ~ 2.5 v
(Coolant temperature is over 70 C)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-43
HOT FILM AIR MASS (HFM) SENSOR
1. Housing
4. Connector
2. Protector net
5. Hot film air mass Sensor
3. Electronic housing
6. Measuring port
The Hot Film Air Mass (HFM) sensor with recognition of flow direction related to pulsating flow is designed for recording
load on Engine Control Module (ECM) by measuring the output voltage proportional to the reference voltage of the ECM.
Mass Air Flow Sensor

Mass Air Flow (MAF) is a thermal flow meter whose sensor element with its temperature sensors and heating area is
exposed to the MAF to be measured. A heating area located in the center of a thin membrane is controlled to an overtemperature by a heating resistor and a temperature sensor of this membrane. And the value of over-temperature
depends on the temperature of the in-flowing air.
Two temperature sensors on upstream and downstream of the heating area show the same temperature without incoming flow. With incoming flow, upstream part is cooled down but downstream temperature retains its temperature more or
less due to the air heated up in the heating area. This temperature difference in quantity and direction depends on the
direction of the incoming flow.
ECM modulates the flow of heating current to maintain the temperature differential between the heated film and the
intake air at a constant level. The amount of heating current required to maintain the temperature thus provides an index
for the MAF. This concept automatically compensates for variations in air density, as this is one of the factors that
determines the amount of warmth that the surrounding air absorbs from the heated element. MAF sensor is located
between the air filter and the throttle valve.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
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1F-44
Under high fuel demands, the MAF sensor reads a high mass flow condition, such as Wide Open Throttle (WOT). The
ECM uses this information to enrich the mixture, thus increasing the fuel injector on-time, to provide the correct amount
of fuel. When decelerating, the mass flow decreases. This mass flow change is sensed by the MAF sensor and read by
the ECM, which then decreases the fuel injector on-time due to the low fuel demand conditions.
To facilitate the installation of the HFM in the intake passage, lubricating agents may be used. However, when lubricants
are used care must be taken to ensure that they do not enter the flow passage and cannot be sucked in with the air flow.
The following tables show the relationship between MAF and output voltage.
Mass Air Flow (kg/h)
Voltage (V)
Mass Air Flow (kg/h)
Voltage (V)
0.95 ~ 1.05
250
3.51
10
1.28
370
3.93
15
1.41
480
4.23
30
1.71
640
4.56
60
2.16
800
4.82
120
2.76
Intake Air Temperature

The Intake Air Temperature (IAT) sensor is a part of Hot Film Air Mass (HFM) sensor and is a thermistor, a resistor which
changes value based on the temperature of the air entering the engine. Low temperature produces a high resistance,
while high temperature causes a low resistance as the following table.
The ECM provides 5 volts to the IAT sensor through a resistor in the ECM and measures the change in voltage to
determine the IAT. The voltage will be high when the manifold air is cold and low when the air is hot. The ECM knows the
intake IAT by measuring the voltage.
The IAT sensor is also used to control spark timing when the manifold air is cold.
Temp. (C)
R min.(
)
R nom. (
)
R max. (
)
-40
35,140
39,260
43,760
-20
12,660
13,850
15,120
5,119
5,499
5,829
20
2,290
2,420
2,551
40
1,096
1,166
1,238
60
565
609
654
80
312
340
370
100
184
202
222
120
114
127
141
130
91
102
114
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ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-45
Failur Code
Description
Trouble Area
Maintenance Hint
03
Intake air temperature

sensor low voltage
IAT sensor short circuit to

ground or open
04

sensor high voltage
IAT sensor short circuit to power
05

sensor plausibility
09

plausibility
Monitoring the actual air temperature through scan tool

bad contact
Inspection the IAT sensor
(integrated in HFM sensor)
Inspection the ECM
Monitoring the actual air mass
flow through scan tool
bad contact
Inspection the MAF sensor
(integrated 11 in HFM sensor)
Inspection the ECM
Malfunction in recognition of IAT

When functional problem
Malfunction in recognition of
MAF
When air mass not plausible
10

low voltage
MAF sensor short circuit to

ground or open
11

high voltage
MAF sensor short circuit to

power
Circuit Description
The heated element on the MAF is a platinum film resistor (heater). It is located on a ceramic plate together with the other
elements in the bridge circuit. The temperature sensitive resistor (flow sensor) also included in the bridge. The separation
of heater and flow sensor facilitates design of the control circuitry. Saw cuts are employed to ensure thermal decoupling
between the heating element and the intake air temperature (IAT) sensor. The complete control circuitry is located on a
single layer. The voltage at the heater provides the index for the mass air flow. The MAFs electronic circuitry then converts
the voltage to a level suitable for processing in the ECM. This device does not need a burn off process to maintain its
measuring precision over an extended period. In recognition of the fact that most deposits collect on the sensor elements
leading edge, the essential thermal transfer elements are located downstream on the ceramic layer. The sensor element
is also design to ensure that deposits will not influence the flow pattern around the sensor.
The IAT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies 5 volt reference and a
ground to the sensor. When the air is cold, the resistance is high; therefore the IAT signal voltage will be high. If the
intake air is warm, resistance is low; therefore the IAT signal voltage will be low.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
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AFFECTED VIN
1F-46
Mass Air Flow Sensor Input Voltage Inspection

2. Measure the signal voltage between the ECM pin
Application
Engine
status
Specified Value
Ignition ON
0.9 ~ 1.1 v
Idling
1.3 ~ 1.7 v
(Coolant temperature is over 70 C)
Notice
If the measured value is not within the specified value, the possible cause may be in cable or MAF sensor
in itself. Perform the 5 volt power supply inspection procedures.
Mass Air Flow Sensor 5 volt Power Supply Inspection

2. Disconnect the HFM sensor connector.
4. Measure the voltage between the ECM pin No. 108 and MAF sensor connecter terminal No. 3.
Specified value
4.7 ~ 5.2 V
Notice
If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling.
Specified value
4.7 ~ 5.2 V
Notice
If the measured value is not within the specified value, the possible cause may be in cableor ECM coupling.
Mass Air Flow Sensor 12 volt Power Supply Inspection

Specified value
11 ~ 14 V
Notice
If the measured value is not within the specified value, the possible cause may be in cable or Over Voltage
Protection Relay (OVPR).
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ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-47
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. Artificial resin housing
4. Connector
2. Metal housing
5. Engine coolant temperature sensor
3. NTC (Negative Tcemperature Coefficient) resistor
Engine Coolant Temperature (ECT) sensor detects coolant temperature and supplies information to the ECM. It is
composed of metal housing with two NTC resistor, 4 pin connector. The ECM provides a 5 volt signal to the ECT sensor
through a dropping resistor. When the engine is cold, the ECT sensor provides high resistance, which the ECM detects
as a high signal voltage. As the engine warms up, the sensor resistance becomes lower, and the signal voltage drops.
At normal engine operating temperature, the ECT signal will measure about 1.5 to 2.0 volts.
The ECM uses information about coolant temperature to make the necessary calculations for:
Fuel delivery
Ignition control
Knock sensor system
Idle speed
Torque converter clutch application
Canister purge
Cooling fan operation
Others
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
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1F-48
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Temperature (C)
)
Resistance (
Voltage (V)
-40
48,550
4.90
-30
27,000
4.82
-20
15,570
4.70
-10
9,450
4.52
5,890
4.43
10
3,790
3.96
20
2,500
3.57
30
1,692
3.14
40
1,170
2.70
50
826
2.26
60
594
1.86
70
434
1.51
80
322
1.22
90
243
0.98
100
185
0.78
110
143
0.63
120
111.6
0.50
130
88
0.40
140
71.2
0.33
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-49
Failur Code
Description
Trouble Area
00
Engine coolant
temperature sensor low
voltage
ECT sensor short circuit to

ground or open
01
Engine coolant
temperature sensor
high voltage
ECT sensor short circuit to

power
Engine coolant
temperature sensor
plausibility
02
Engine coolant
temperature insufficient
for closed loop fuel
control
06
Malfunction in recognition of ECT

When drop to about 50C below
after warm up
Maintenance Hint
Monitoring the actual coolant

temperature through scan tool
bad contact
Inspection the ECT sensor
Inspection the ECM
Malfunction in recognition of ECT

When minimum temperature for
lambda control after warm up
Circuit Description
The ECT sensor uses a thermistor to control the signal voltage to the ECM. The ECM supplies a voltage on the signal
circuit to the sensor. When the engine coolant is cold, the resistance is high; therefore the ECT signal voltage will be high.
Engine Coolant Temperature Sensor Inspection

2. Measure the voltage between the ECM pin No. 78 and No. 79.
Temperature (C)
Specified Value (V)
20
3.57
80
1.22
100
0.78
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
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1F-50
4. Disconnect the ECT sensor connector.
6. Measure the resistance between the ECT sensor terminal pin No. 1 and No. 4.
Temperature (C)
Specified Value (V)
20
2,500
80
322
100
185
Notice
Replace wiring and coolant temperature sensor if out of specified value.
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ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-51
ACCELERATOR PEDAL MODULE
1. Accelerator pedal
4. 6-pin connector
2. Accelerator pedal sensor
5. Bolt
3. Bolts
The Acceleration Pedal Position (APP) sensor is mounted on the accelerator pedal assembly. The sensor is actually
two individual APP sensors and one housing. This sensor works with the Throttle Position (TP) sensor to provide input
to the Engine Control Module (ECM) regarding driver requested accelerator pedal and throttle angle at the throttle body.
When the APP Sensor is Defected

When the APP1 or APP 2 sensor is defected condition, the engine is still running at idle condition but, the accelerator
pedal reaction is not response correctly and also, the engine rpm will be reacted to 4,000 rpm slowly. If the APP 1
sensor is out of order, the APP 2 sensor will be conducted with signal as a default signal but, the throttle valve opening
is limited 60% and delayed opening speed.
When the TP Sensor or Servo Motor is Defected

When the TP 1, 2 sensor or servo motor is defected condition, the throttle valve will be closed to the spring capsule by
spring force, at this condition, the throttle valve will open 10 ~ 20and engine rpm will be controlled by ECM with opening
(ON/OFF) time of injector. The engine rpm will be maintaining 900 rpm (at idle) to 1,800 according to the engine load.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-52
Failur Code
Description
Trouble Area
122
Acceleration pedal
position sensor signal
failure
When malfunction of APP

sensor
160
Acceleration pedal
position 1 sensor low
voltage
APP 1 sensor short circuit to

ground or open
161
Acceleration pedal
position sensor 1 high
voltage

power
162
Acceleration pedal
position sensor 2 low
voltage

ground or open
163
Acceleration pedal
position sensor 2 high
voltage

power bad contact
164
Accelerator pedal
position sensor 1 not
plausible with
accelerator pedal
position sensor 2
When difference between APP 1

sensor and APP 2 sensor
167
Both setpoint
accelerator pedal
position sensor
defective
When defective of both APP

sensor
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Maintenance Hint

through scan tool
or open with
Inspection the APP sensor
Inspection the ECM
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-53
Circuit Description
The ECM supplies a 5 or 2.5 volt reference signal and a ground to the APP sensor 1or 2. The ECM calculates on these
signal lines. The APP sensor output changes as the accelerator pedal is moved. The output of the APP 1and APP2
sensor are low, about 0.4 ~ 0.7 volts and 0.2 ~ 0.35 volts respectively at the closed throttle position. As pushing the
accelerator pedal, the output increases so that the output voltages will be about 4.3 ~ 4.8 volts and 2.1 ~ 2.4 volts
individually when accelerating fully with the kick down, at Wide Open Throttle (WOT).
Acceleration Pedal Position Sensor 1 Inspection

2. Measure the signal voltage between the ECM pin No. 47andNo. 31while operating the accelerator pedal as following
conditions.
Not depress the pedal (closed throttle position)
Fully depress the pedal (full throttle with kick down)
Condition of Throttle Valve
Specified Value (V)
Closed throttle valve
0.3 ~ 0.7
Fully depressed throttle valve
4.3 ~ 4.8
Notice
If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to
APP 1 sensor.
Acceleration Pedal Position Sensor 2 Inspection

2. Measure the signal voltage between the ECM pin No. 48 and No. 50 while operating the accelerator pedal as
following conditions.
Not depress the pedal (closed throttle position)
Fully depress the pedal (full throttle with kick down)
Condition of Throttle Valve
Specified Value (V)
Closed throttle valve
0.1 ~ 0.4
Fully depressed throttle valve
2.1 ~ 2.5
Notice
If measured value is not within the specified value, check the pedal valve sensor and the supply voltage to
APP sensor 2.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-54
COOLING FAN
Failur Code
Description
Trouble Area
44
Cooling fan (HI) relay

short circuit to power
Cooling fan short circuit to power
45
Cooling fan (HI) relay

or open
Cooling fan short circuit to

ground or open with bad contact
Maintenance Hint
Inspection the power source
Inspection the cooling fan
Inspection the ECM
Circuit Description
Ignition voltage is supplied directly to the cooling fan relay coil. The ECM controls the relay by grounding the control
circuit. When the ECM is commanding a command ON, the voltage of the control circuit should be low (near 0 volt).
When the ECM is commanding the control circuit should be high (near battery voltage). If the fault detection circuit
senses a voltage other than what is expected, the fault line status will change causing the fault code to set.
CHANGED BY
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-55
A/C COMPRESSOR RELAY
Failur Code
Description
228
A/C compressor relay

Trouble Area
Monitoring the actual operation

through scan tool
When malfunction of A/C
compressor control
229
A/c compressor relay

or open
Maintenance Hint

Inspection the relay short circuit
or open
Inspection the ECM
Circuit Description
When the ECM detects that A/C has been requested, the ECM will activated the A/C clutch relay. When the relay has
been activated, voltage should be present at both the A/C clutch relay and A/C switch circuit at ECM.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-56
CRUISE CONTROL SWITCH
Failur Code
Description
Trouble Area
129
Cruise control OFF

due to message
counter failure
Cruise control system

message counter fault
130
Vehicle speed signal

failure
131

failure
132
Cruise control lever

failure
Cruise control lever

defective
133
Cruise control
acceleration failure
Cruise control system Implausible condition of acceleration

signal
134
Cruise control
deceleration failure
Cruise control system Implausible condition of deceleration

signal
When malfunction of auto-cruise

system Implausible condition of
vehicle speed signal.
Maintenance Hint
Monitoring the actual recognition

status and vehicle speed signal
through scan tool
Module (ECM) pin 52 53 54 55 57
bad contact
Inspection the CAN and ABS
Inspection the cruise control lever
switch
Inspection the ECM
Circuit Description
Cruise control is an automatic speed control system that maintain a desired driving speed without using the accelerator
pedal. The vehicle speed must be greater than 40 km/h to engage cruise control.
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ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-57
RESONANCE FLAP
Failur Code
228
229
Description
Resonance flap short

circuit to battery
Resonance flap short

open
Trouble Area
Resonance flap short circuit to

power
Resonance flap short circuit to

ground or open
Maintenance Hint
through scan tool
Inspection the power source short
circuit or open to resonance flap
Inspection the resonance flap
solenoid and hardware
Inspection the ECM
Circuit Description
A pneumatically actuated resonance flap is located on the intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled by ECM and rpm.
Resonance flap is closed at idle/partial load (less than 3,800/rpm). The switch valve will be adjusted by ECM and
resonance flap will be closed. By increasing air flow passage through dividing intake air flow toward both air collection
housing. This leads to a significant increase in the torque in the lower speed range.
Resonance flap is open at full load (over 3,800/rpm). The switch valve will not be adjusted by ECM and resonance flap will
be open. The collected air in the air collection housing will not be divided and intake air passage will be shorten.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
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AFFECTED VIN
1F-58
STOP LAMP SWITCH
Failur Code
Description
Trouble Area
Maintenance Hint
through scan tool
135
Stop lamp switch failure
When malfunction of stop lamp

switch - implausible condition of
stop lamp signal input

Inspection the contact condition of
stop lamp switch
Inspection the ECM
Circuit Description
The stop lamp switch is normally opened. When the ignition switch ON and brake ON, the battery voltage is supplied to
the ECM. A scan tool should display ON when brake pedal is depressed and should read OFF with brake pedal released.
CHANGED BY
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-60
EXHAUST SYSTEM
CATALYTIC CONVERTER
The purpose of the catalytic converter is to convert the
three pollutants of carbon monoxide(CO), hydrocarbons
(HC) and oxides of nitrogen (NOx) contained in the exhaust of gasoline engines, into the harmless compounds
of water (H2O), carbon dioxide (CO2) and nitrogen (N2).
The catalytic converter contains a catalyst, a word coming from the Greek and which designates the element
essential for catalyst which triggers chemical reactions
without itself being consumed.
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These catalysts in the 3-way catalytic converter are the

rare metals platinum (Pt) and rhodium (Rh).
The catalytic converter consists essentially of three main
elements. The exhaust gases flow through the catalytic
converter and, in so doing, coming into contact with rare
metals (Pt and Rh).
The following chemical reaction are produced.
CO + O2 CO 2
HC + O2 CO2 + H2O
NOx
N2 + O2
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-61
OXYGEN SENSOR
The oxygen sensor is unique among the engine control

sensors because is acts like a battery and is able to
generate its own low voltage signal. It is located the exhaust system and monitors the amount of oxygen in the
exhaust stream and provides feedback to the Engine
Control Module (ECM).
The electrically heated oxygen sensor warms up quickly
and remains hot, even at idle when the exhaust manifold
may cool down.
When the exhaust gas is rich (below 14.7 : 1), the voltage
output is high, above 450 mv. When the exhaust gas is
lean (above 14.7 : 1 air/fuel ratio), the sensors voltage
output is low, below 450 mv.
The ECM uses oxygen sensor information for:
Open loop / closed loop criteria
Ideal air / fuel ratio
The ECM applies a reference voltage of 450 mv to the

oxygen sensor, the ECM compares this reference voltage with the voltage generated by oxygen sensor. The
amount of voltage the oxygen sensor generates is proportionate to the difference between the amount of oxygen in the outside air and the exhaust gases. The atmosphere contains about 21% oxygen. The exhaust from a
rich air/fuel ratio contains almost no oxygen. With a large
difference between the amounts of oxygen containing the
two surface, the sensor generates less voltage.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-62
CHANGED BY
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-63
Failur Code
Description
Trouble Area
80
Oxygen sensor high

voltage
When recognition the output that

more than nominal threshold,
malfunction of sensing voltage.
89
Oxygen sensor low

voltage

more than nominal threshold,
malfunction of sensing voltage.
82
Oxygen sensor no
activity detected

not active the sensor etc.
83
Oxygen sensor not lean

after overrun fuel
shut-off

no lean signal after overrun fuel
shut-off
84
Oxygen sensor slow

response
When slow response of sensor

signal
85
Oxygen sensor heater

failure
When recognition the heating

circuit


currents that more or less than
set values (less than 0.2A or
more than 2A)

or open

voltages than less than set
values (less than 2V)
86
87
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Maintenance Hint
Monitoring the actual output

signal through scan tool
bad contact
Inspection the oxygen sensor
Inspection the ECM
Monitoring the heating status

through scan tool
Inspection the heating power source
Inspection the heating circuit of
oxygen sensor
Inspection the ECM
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AFFECTED VIN
1F-64
Failur Code
Description
Trouble Area
Maintenance Hint
81
Bank 1 system short

term fuel trim
adaptation below lean
threshold
When recognition the value less

than nominal control threshold, it
means that when big deviation in
control range of adaptation
values through fuel and air
mixture formation
93
Bank 1 system short

term fuel trim
adaptation above rich
threshold
When recognition the value more

than nominal control threshold, it
means that when big deviation in
control range of adaptation
values through fuel and air
mixture formation
96
Bank 1 system short

term fuel trim at rich
stop
When recognition the short term

fuel trim that more than nominal
threshold
Bank 1 system short

term fuel trim at lean
stop
When recognition the short term

fuel trim that less than nominal
threshold
Inspection the intake air leakage
97
When recognition the long term

fuel trim exceeds rich threshold
Inspection the exhaust leakage
98
Bank 1 system idle

adaptation failure
(above rich threshold)
99
Bank 1 system idle

adaptation failure
(below rich threshold)

fuel trim exceeds lean threshold
100
Bank 1 system learning

control failure
(rich, low load)

101

control failure
(lean, low load)

102

control failure
(rich, high load)

103

control failure
(rich, low load)

Inspection the injection quantities

with injector block or leakage
Inspection the ECM
Circuit Description
In order to control emissions, a catalytic converter is used to covert harmful emissions into harmless water vapor and
carbon dioxide. The ECM has the ability to monitor this process by using a oxygen sensor. The oxygen sensor produces
and output signal which indicates the storage capacity of the catalyst. This in turn indicates the catalysts ability to
convert exhaust emission effectively. If the oxygen sensor pig tail wiring, connector, or terminal is damaged. Do not
attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly, it must have a clean air
reference provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair
the wires, connector, or terminal and degrade the oxygen sensor performance.
CHANGED BY
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-65
Oxygen Sensor Signal Voltage Inspection

1. Maintain the engine speed is at idle while the coolant temperature is over 80 C.
2. Measure the oxygen sensor signal voltage between the ECM terminal No. 16 and No. 17.
Specified value
0.2 ~ 1.0 V
Notice
If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor
or ECM.
Oxygen Sensor Heating Voltage Inspection

1. Maintain the engine speed is at idle while the coolant temperature is over 80 C.
2. Measure the oxygen sensor signal voltage between the ECM terminal No. 11 and No. 9.
Specified value
11 ~ 14 V
Notice
or ECM.
Oxygen Sensor Heating Current Consumption Inspection

2. Measure the oxygen sensor heating current consumption between the ECM terminal No. 9 and No. 5.
Specified value
0.2 ~ 2.0 A
Notice
or ECM.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
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AFFECTED VIN
1F-66
ENGINE CONTROL MODULE
1.
2.
3.
4.
Cover
Plate
Connector
Flat pin
Vehicle side: No. 1-12
Engine side: No. 61-72
5. Pin
Vehicle side: No. 13-60
Engine side: No. 73-120
A. Vehicle side connector: Black
B. Engine side connector: Gray
The Engine Control Module (ECM), located inside the right side kick panel, is the control center of the fuel injection
system. It constantly looks at the information from various sensors and controls the systems that affect the vehicles
performance. Engine rpm and air mass are used to measure the air intake quantity resulting in fuel injection metering.
The ECM also performs the diagnostic functions of the system. It can recognize operational problems, store failure code(s)
which identify the problem areas to aid the technician in making repairs.
There are no serviceable parts in the ECM. The calibrations are stored in the ECM in the Programmable Read Only
Memory (PROM).
The ECM supplies either 5 or 12 volts to power the sensors or switches. This is done through resistance in the ECM
which are so high in value that a test light will not come ON when connected to the circuit. In some cases, even an
ordinary shop voltmeter will not give and accurate reading because its resistance is too low. You must use a digital
voltmeter with a 10 Mohm input impedance to get accurate voltage readings. The ECM controls output circuits such as
the ignition coils, the fuel injectors, the fuel pump relay, the intake manifold resonance flap, the camshaft actuator, the
canister purge valve, etc., by controlling the ground circuit.
CHANGED BY
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AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-67
SERIAL DATA COMMUNICATION
Failur Code
23
Description
CAN communication
failure: ASR/MSR
Trouble Area
When CAN signal message

missing or implausibility for
ASR/MSR unit or not
initialized condition
Maintenance Hint
Inspection the ASR unit with CAN
connection
Module (ECM) pin 38, 37 about short
Inspection the ECM
24
CAN communication
failure: ABS

missing or implausibility for ABS
unit or not initialized condition
Inspection the ABS unit with CAN

connection
Inspection the ECM pin 38, 37 about
Inspection the ECM
26
CAN communication
failure: TCU (A/T only)

missing or implausibility for TCU
unit or not initialized condition
Inspection the TCM unit with CAN

connection
Inspection the ECM pin 38, 37 about
Inspection the ECM
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-68
Failur Code
27
Description
Trouble Area
CAN communication failure: TOD

(E32 only)

TOD unit or not initialized
condition
Maintenance Hint
Inspection the TOD unit with CAN connection
Inspection the ECM pin 38, 37 about short
Inspection the ECM
29
CAN communication failure: ID 200h

not plausible

ABS/ESP unit or not initialized condition
Inspection the ABS/ESP unit with CAN

connection
Inspection the ECM
30
CAN communication failure: ID 208h

not plausible

ABS/ESP unit or not
initialized condition
Inspection the ABS/ESP unit with CAN

connection
Inspection the ECM
31
CAN communication failure: communication initialization failure

each unit
(ABS, ASR, TCM, TOD etc.)
or not initialized condition
Inspection the each control unit with CAN

connection
Inspection the ECM
Inspection the MSR unit with CAN connection
59
CAN communication failure: MSR

data transmission
not plausible

MSR unit or not initialized
condition
Inspection the Engine Control Module (ECM)

pin 38, 37 about short circuit or open with
bad contact
Inspection the ECM
Inspection the ASR unit with CAN connection
60
CAN communication failure: ASR

data transmission
not plausible

ASR unit or not initialized
condition
Inspection the Engine Control Module

(ECM) pin 38, 37 about short circuit or open
with bad contact
Inspection the ECM
Circuit Description
The provision for communicating with the ECM is the Data Link Connector (DLC). It is located in the instrument panel
fuse block. The DLC is used to connect the scan tool. Battery power and ground is supplied for the scan tool through the
DLC. CAN line is used to communicate with the other module such as the Transmission Control Module (TCM) and
Transfer Case Control Unit (TCCU).
Keyword 2000 Serial Data Communications

Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by transmitting and receiving multiple signals over a singles wire. The message carried on KWP 2000 data streams are also
prioritized. If two messages attempt to establish communications on the data line at the same time, only the message
with higher priority will must wait.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-69
INTERNAL FAILURE
Failur Code
Description
Trouble Area
Maintenance Hint
Inspection the coding condition
through scan tool
Transmission coding
failure
21
When faulty of variant coding of

transmission

Module (ECM)
Inspection the CAN line
Inspection the TCM
136
ECM failure (RAM)
When malfunction of random

access memory - ECM internal
error
142
Uncoded/unprogramed
ECM
When malfunction of ECM

coding-required ECM
encoding
Fulfill the ECM variant coding
137
ECM failure (EPROM)
143
ECM failure (EEPROM/

Flash - EPPOM
checksum failure)
144
ECM failure (coding ID

checksum failure)
When malfunction of ECM

internal
Inspection the ECM
145
ECM failure (coding

checksum failure)
146
ECM failure
(programming
checksum failure)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Inspection the ECM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-70
ELECTRONIC THROTTLE CONTROLLER SAFETY MALFUNCTION

Failur Code
Description
110
Throttle actuator
learning data fault
117
Exceed fuel-cut safety time
120
Cruise control
interruption memory failure
138
Call Monitoring
139
Servo motor control output

interruption memory failure
140
Servo motor open/short
186
ECM failure
(incompatible CPU)
187
ECM failure (CPUs communication failure)
188
ECM failure (CPU 2 configuration

failure)
189
ECM failure (CPU 2 fault)
190
ECM failure (CPU run time

failure between CPUs)
231
ECM failure (CPU 2 cruise

control message counter failure)
232
Over deceleration limit (CPU 2)
233
Over acceleration limit (CPU 2)
234
Cruise control lever dual operation (CPU 2)
235
Cruise control lever safety

terminal failure (CPU 2)
236
Unusual pedal position variation

(CPU 2)
237
Unusual throttle position variation

(CPU 2)
238
Unusual throttle
controller monitoring data
comparison fault (CPU 2)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Trouble Area
System internal failure
Maintenance Hint

Module (ECM)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-71
Failur Code
Description
239
Unusual accelerator pedal

position sensor comparison fault
(CPU 2)
240
Maintenance Hint
Throttle potentiometer comparison fault (CPU 2)
241
Unusual CPU
communication (CPU 2)
242
Unusual CPU
configuration (CPU 2)
243
A/D converter failure (CPU 2)
244
Accelerator pedal position

sensor setpoint fault between
CPU 1 and CPU 2 (ECM)
245
Position controller setpoint

fault between CPU 1 and CPU 2
246
MSR setpoint fault between CPU

1 and CPU 2
247
Idle control setpoint fault between CPU 1 and CPU 2
248
A/D converter overflow (CPU 2)
249
ROM fault (CPU 2)
250
RAM fault (CPU 2)
251
Cycle monitor fault (CPU 2)
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
Trouble Area
System internal failure

Module (ECM)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-72
IMMOBILIZER
Failur Code
Description
Trouble Area
Maintenance Hint
D Inspection the Engine Control
Module (ECM) pin 13, 14 about
25
Communication with
transponder missing
When missing the

transponder signal
Inspection the power source or

ground short circuit or open of
immobilizer unit
Inspection the transponder
condition (broken etc.)
Inspection the ECM
When malfunction of immobilizer

141
Unprogramed ECM with

immobilizer
Required immobilizer encoding,

no paired condition of immobilizer even through start trial
Fulfill the immobilizer pairing
Circuit Description
Immobilizer is a device disabling vehicle ignition unless a specific key is used and designed to help prevent vehicle theft.
Immobilizer is comprised of two devices, a key with encoded transponder and ECM with the same encoding of the
transponder. When a key is inserted into the hole to start vehicle and turned to ON, the ECM reads and decodes the
transponder code and, if the same, starts the engine, it is called immobilizer. It means immobilizer system disables
starting by stopping fuel supply if the code in the transponder does not match the code stored in ECM each other.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-73
MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
DISCHARGING THE PRESSURE IN
FUEL SYSTEM
Installation
Specified value
25 Nm (18 lb-ft)
2. Remove the fuel pressure in fuel system by pressing the

service valve with a clean, pointy tool.
Notice
Place a cloth so that the fuel doesnt stain around.
reverse order.
FUEL PUMP
Tools Required
A9922 0012A (661 589 00 46 00)
Fuel Tank Cap Wrench

Caution
The fuel system is under pressure. To avoid fuel
spillage and the risk of personal injury or fire, it is
necessary to relieve the fuel system pressure before
disconnecting the fuel lines.
1. Relieve the fuel system pressure. Refer to Discharging
the Pressure in Fuel System in this section.
3. Remove the fuel pump wiring connectors.
4. Disconnect the fuel supply and return pipes.
5. Remove the fuel pump locking cap band.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-74
8. Using the fuel tank cap wrench 661 589 00 46 00, remove
the locking cap.
9. Remove the pump from the fuel tank.
Notice
Check the condition of the seal and replace if
necessary. Drain the fuel before removing the pump.
10. Perform an operational check of the fuel pump.
reverse order.
FUEL FILTER
Caution
2. Relieve the fuel system pressure. Refer to Discharging
the Pressure in Fuel System in this section.
3. Disconnect the fuel lines from the fuel filter.
Installation
Tightening torque
28 Nm (21 lb-ft)
4. Remove the fuel filter mounting bracket bolt.

Installation
Tightening torque
28 Nm (21 lb-ft)
Notice
Place the fuel pump pad. There may be a corrosion
due to the contact between the fuel filter and the
bracket.
5. Remove the fuel filter.
6. Install the fuel filter.
7. Perform a leak test of the fuel filter.
reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-75
FUEL TANK
Caution
1. Relieve the fuel pressure. Refer to Discharging the
Pressure in Fuel System in this section.
3. Drain the fuel tank.
4. Disconnect the return line.
5. Disconnect the supply line.
6. Disconnect the fuel tank-to-canister hose from the fuel
tank.
7. Disconnect the fuel pump wiring connector.
8. Disconnect the fuel supply hose, fuel return hose.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-76
9. Unscrew the bolts and remove the fuel filler pipe from the
fuel filler opening.
10. Install the safety jack under the fuel tank and remove the
bolts (12mm x 4) from the fuel tank.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-77
11. Carefully lower the safety jack with the fuel tank.
Caution
Be careful not to drop the fuel tank while removing
it.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-78
FUEL PRESSURE REGULATOR

Installation
Tightening torque
25 Nm (18 lb-ft)
Caution
3. Relieve the fuel pressure in fuel supply system by
pressing the service valve.
4. Disconnect the vacuum hose.

5. Disconnect the circlip and remove the fuel pressure
regulator.
6. Apply the oil to O-ring lightly and then replace it.
7. Perform a leak test of the fuel pressure regulator with the
engine off and the ignition on.
reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-79
FUEL RAIL AND INJECTORS

Caution
The fuel system is under pressure. To avoidfuel spillage
and the risk of personal injury or fire, it is necessary to
relieve the fuel system pressure before disconnecting the
fuel lines.
1. Discharge the fuel pressure from the fuel pressure test
connector.
3. Disconnect the vacuum hose from the fuel pressure
regulator.
4. Remove the cable guide.
5. Disconnect the Hot Film Air Mass (HFM) sensor
connector.
6. Remove the intake air duct mounting bolts.
Installation
Tightening torque
9 Nm (80 lb-ft)
7. Remove the intake air duct clamps.

8. Remove the intake air duct.
9. Remove the fuel return and supply line.
Notice
For removal, cover around parts with cloths not to
be stained by fuel. In case of checking the injector
only, do not remove the fuel return and supply line.
Installation
Tightening torque
23 Nm (17 lb-ft)
10. Remove the six injector connectors.
11. Remove the two left and two right bolts and one center
bolt of the fuel rail assembly from the intake manifold.
Installation
Tightening torque
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
25 Nm (18 lb-ft)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-80
Notice
Before removal, the fuel rail assembly may be cleaned
with as pray type cleaner, following package instructions.
Do not immerse the fuel rails in liquid cleaning solvent.
Use care in removing the fuel rail assembly to prevent
damage to the electrical connectors and injector spray
tips. Prevent dirt and other contaminants from entering
open lines and passages. Fittings should be capped and
holes plugged during service.
Important
If an injector becomes separated from the rail and remains
in the cylinder head, replace the injector O-ring seals and
the retaining clip.
12. Remove the injectors and the fuel rail carefully.
13. Remove the fuel injector retainer clips.
14. Remove the fuel injectors by pulling them down and out.
15. Discard the fuel injector O-rings.
16. Lubricate the new fuel injector O-rings with engine oil.
Install the new O-rings on the fuel injectors.
17. Perform a leak check of the fuel rail and fuel injectors.
reverse order.
ENGINE COOLANT TEMPERATURE

SENSOR
1. Relieve the coolant system pressure.
3. Disconnect the engine coolant temperature sensor
connector.
Notice
Take care when handling the engine coolant
temperature sensor. Damage to the sensor will affect
the proper operation of the fuel injection system.
4. Remove the engine coolant temperature sensor from the
pump hosing.
Installation
Tightening torque
30 Nm (22 lb-ft)

reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-81
THROTTLE BODY (INTEGRATED

WITH THE ACTUATOR)
2. Disconnect the mass air flow sensor connector.
3. Disconnect the mass air flow sensor from the air filter
housing.
4. Remove the intake air duct mounting bolts.
Installation
Tightening torque
9 Nm (80 lb-ft)
5. Remove the air inlet housing clamps.

6. Remove the inlet air housing.
7. Disconnect the throttle body electrical connector.

8. Remove the throttle body bolts.
Installation
Tightening torque
12 Nm (106 lb-ft)
9. Remove the vacuum hose.
10. Remove the throttle body and discard the gasket.

Important
Use care in cleaning old gasket material. Sharp tools
may damage sealing surfaces.
reverse order.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-82
HOT FILM AIR MASS (HFM) SENSOR

2. Disconnect the Hot Film Air Mass (HFM) sensor electrical
connector.
3. Remove the HFM sensor retaining screws.
4. Turn the HFM sensor coupling in the direction shown in
the figure in the left so that it gets separated from the
contact surface.
Notice
Make sure the HFM sensor coupling connects
completely with the contact surface installation.
5. Remove the HFM sensor.
reverse order.
KNOCK SENSOR
2. Disconnect the knock sensor electrical connector from
the intake manifold bracket.
3. Remove the knock sensor mounting bolt from the knock
sensor installed on the cylinder block.
Installation
Tightening torque
25 Nm (18 lb-ft)
4. Remove the knock sensor.

reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-83
PEDAL POSITION SENSOR

2. Disconnect the pedal position sensor connector.
3. Unscrew the bolts and nut.
Installation
Tightening torque
6 Nm (53 lb-ft)
4. Remove the pedal and sensor assembly.

reverse order.
OXYGEN SENSOR
Notice
The oxygen sensor uses a permanently attached
pigtail and connector. This pigtail should not be
removed from the oxygen sensor. Damage or removal
of the pigtail or the connector could affect proper
operation of the oxygen sensor. Do not drop the
oxygen sensor.
2. Disconnect the electrical connector.
3. Carefully remove the oxygen sensor from the exhaust pipe.
Installation
Tightening torque
55 Nm (41 lb-ft)
Important
A special anti-seize compound is used on the oxygen
sensor threads. This compound consists of a liquid
graphite and glass beads. The graphite will burn away,
but the glass beads will remain, making the sensor
easier to remove. New or serviced sensors will already have the compound applied to the threads. If a
sensor is removed from any engine and is to be reinstalled, the threads must have an anti-seize compound
applied before reinstallation.
4. Coat the threads of the oxygen sensor with an anti-seize
compound, if needed.
reverse order.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-84
PURGE CONTROL VALVE

2. Disconnect the purge control valve connector.
3. Disconnect the throttle body-to-purge control valve hose
from the purge control valve.
4. Disconnect the canister-to-purge control valve hose from
the purge control valve.
5. Remove the purge control valve.
reverse order.
CANISTER
Caution
Canister and vacuum hoses contain fuel vapors. Do
not smoke in the area or permit an open flame.
1. Disconnect the fuel tank-to-canister hose form the
canister.
2. Disconnect the canister-to-purge control valve hose form
the canister.
3. Remove the canister mounting bolts.
Installation
Tightening torque
6 Nm (53 lb-ft)
4. Remove the canister.

reverse order.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-85
CAMSHAFT POSITION SENSOR

2. Disconnect the electrical connector from the camshaft
position sensor.
3. Remove the camshaft position sensor retaining bolt.
Installation
Tightening torque
10 Nm (89 lb-ft)
4. Check the O-ring for damage and replace it if neces sary.

reverse order.
CRANKSHAFT POSITION SENSOR

2. Disconnect the electrical connector at the crankshaft
position sensor.
3. Remove the crankshaft position sensor retaining bolt.
Installation
Tightening torque
25 Nm (18 lb-ft)

reverse order.
ENGINE CONTROL MODULE

2. Remove the cowl side trim form passenger side. Refer
to Section 9G, Interior trim.
3. Remove the four securing nuts for the Engine Control
Module (ECM) from the mounting bracket.
Installation
Tightening torque
25 Nm (18 lb-ft)
4. Pull out the ECM from the bracket.

5. Disconnect the vehicle side coupling.
reverse order.
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-86
SCHEMATIC AND ROUTING DIAGRAMS

DIAGNOSIS CIRCUIT
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-87
ECU (GSL G32)

IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-88
O2 SENSOR, PEDAL MODULE, CRUISE CONTROL SW, STOP LAMP SW
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-89
INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-90
SPECIFICATIONS
ENGINE DATA DISPLAY TABLE
Parameter
Unit
Value
Engine coolant temp.
greater than 95C after warm up
Intake air temp.
-40 ~ 130C (varies with ambient

temp. or engine mode)
Engine rpm
rpm
700 50 (P/N), 600 50 (D)
Regular rpm
rpm
700 50 (P/N), 600 50 (D)
Engine load
18 ~ 25 %
Mass air flow meter
Kg/h
16 ~ 25 Kg/h
Throttle position angle
TA
0TA (up to 100TA at t he wi de

open throttle)
Spark advance
CA
CA (6 ~ 9CA)
Indicated engine torque
Nm
Varies with engine condition
Injection time
ms
3 ~ 5 ms
Battery voltage
13.5 ~ 14.1V (engine running)
Front axle speed
Km/h
0 ~ 265 Km/h
Rear axle speed
Km/h
0 ~ 265 Km/h
Accel. Pedal position 1
0.4 ~ 4.8 V
Accel. Pedal position 2
0.2 ~ 2.4 V
Throttle position 1
0.3 ~ 4.6 V
Throttle position 2
0.3 ~ 4.6 V
0.8 ~ 1.2
Fuel integrator
Oxygen sensor
mv
100 ~ 900 mv
A/c s/w condition
1=ON/0=OFF
Full load state
1=ON/0=OFF
Shift gear state (A/T)
1=ON/0=OFF
A/c control state
1=ON/0=OFF
Clutch switch (M/T)
1=ON/0=OFF
Cam actuator state
1=ON/0=OFF
Knocking control
1=ON/0=OFF
Protect mission
1=ON/0=OFF
Purge control valve
1=ON/0=OFF
Lambda function
1=ON/0=OFF
Catalyst heating
1=ON/0=OFF
Overrun fuel cut
1=ON/0=OFF
Ful l fuel cut
1=ON/0=OFF
Brake switch
1=ON/0=OFF
Cruise control status
1=ON/0=OFF
* Condition: Warmed up, idle, P/N or neutral
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-91

Application
Nm
Lb-Ft
Lb-In
Camshaft position sensor retaining bolts
10
89
Canister mounting bolts
53
Coolant temperature sensor
30
22
Crankshaft position sensor retaining bolt
10
89
Engine Control Module (ECM) mounting bracket nuts
10
89
Fuel filter mounting bracket bolt
53
Fuel filter lines
28
21
Fuel pressure test connector
25
18
Fuel rail assembly bolts
25
18
Fuel return and supply lines
23
17
Fuel tank retaining nuts
38
28
Intake air duct mounting bolts
80
Knock sensor mounting bolt
25
18
Oxygen sensor
55
41
Pedal position censor mounting bolts and nut
53
Throttle body bolts
12
106
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1F-92
FUEL SYSTEM SPECIFICATION

Use Only Unleaded Fuel Rated at
89 Octane or Higher
Fuel quality and additives contained in fuel have a significant effect on power output, drivability, and life of theengine.
Fuel with too low an octane number can cause engine
knock.
Caution
Use of fuel with an octane number lower than 89 may
damage engine and exhaust system.
Notice
To prevent accidental use of leaded fuel, the nozzles
for leaded fuel are larger, and will not fit the fuel filler
neck of your vehicle.
Do Not Use Methanol

Fuels containing methanol (wood alcohol) should not be
used in vehicle.
This type of fuel can reduce vehicle performance and damage components of the fuel system.
Caution
Use of methanol may damage the fuel sys-tem.
Vehicle Fueling from Drums or

Storage Containers
For safety reasons (particularly when using noncommercial fueling systems) fuel containers, pumps and
hoses must be properly earthed.
Static electricity build up can occur under certain atmospheric and fuel flow conditions if unearthed hoses, particularly plastic, are fitted to the fuel-dispensing pump.
It is therefore recommended that earthed pumps with integrally earthed hoses be used, and that storage containers be properly earthed during all noncommercial fueling operations.
TEMPERATURE VS RESISTANCE
C
ECT Sensor
IAT Sensor
ohms ()
Temperature vs Resistance Values (Approximate)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
130
266
88
102
120
248
111.6
127
110
230
143
159
100
212
202
202
90
194
261
261
80
176
340
340
70
158
452
452
60
140
609
609
50
122
835
835
40
113
1166
1166
30
86
1662
1662
20
68
2420
2420
10
50
3604
3604
32
5499
5499
-10
14
8609
8609
-20
-4
13850
13850
-30
-22
22960
22960
-40
-40
39260
39260
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
1F-93

A9922 0012A (103 589 00 21 00)
Fuel Pressure Gauge
ENGINE CONTROLS
M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1G-1
SECTION
00 1G
ENGINE INTAKE & EXHAUST

Table of Contents
DESCRIPTION AND OPERATION .................................. 1G-2
Exhaust system .......................................................... 1G-2
Muffler ........................................................................ 1G-2
Catalytic converter ..................................................... 1G-2
Catalytic converte structure ....................................... 1G-3
Catalytic converter and temperature ......................... 1G-3
Purification of catalytic converter .............................. 1G-4
Resonance flap .......................................................... 1G-5
REPAIR INSTRUCTIONS ................................................ 1G-6
ON-VEHICLE SERVICE .................................................. 1G-6
Air cleaner and intake air duct .................................. 1G-6
Intake manifold ........................................................... 1G-9
Resonance flap ........................................................ 1G-10
Exhaust line .............................................................. 1G-11
SPECIFICATIONS ......................................................... 1G-14
Fastener tightening specifications .......................... 1G-14

M162 GSL ENG SM - 2005.7
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1G-2

EXHAUST SYSTEM
CATALYTIC CONVERTER
Notice
When you are inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to avoid possible
overheating of the floor panel and possible damage
to the passenger compartment insulation and trim
materials.
Notice
When jacking or lifting the vehicle from the body side
rails, be certain that the lift pads do not contact the
catalytic converter, as this could damage the catalytic
converter.
Check the complete exhaust system and the nearby body

areas and trunk lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose
connections, or other deterioration which could permit
exhaust fumes to seep into the trunk may be an indication of a problem in one of these areas. Any defects should
be corrected immediately.
MUFFLER
Notice
Use of anything other than unleaded fuel will damage
the catalyst in the catalytic converter.
The catalytic converter are emission-control devices added
to the exhaust system to reduce pollutants from the exhaust pipes.
The oxidation catalyst is coated with a catalytic material
containing platinum and palladium, which reduces levels
of hydrocarbon (HC) and carbon monoxide (CO) from the
exhaust gas. The three-way catalyst has coatings which
contain platinum and rhodium, which additionally lower
the levels of oxides of nitrogen (NOx).
Aside from the exhaust manifold connection, the exhaust

system uses a flange and seal joint design rather than a
slip joint coupling design with clamp and U-bolts. If hole,
open seams, or any deterioration is discovered upon inspection of the front muffler and pipe assembly, the complete assembly should be replace, the complete assembly should be replaced. The same procedure is applicable
to the rear muffler assembly.
Heat shields for the front and rear muffler assembly and
catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

M162 GSL ENG SM - 2005.7
1G-3
CATALYTIC CONVERTE STRUCTURE

The Catalytic converter of monolith type consists of 2 walled
metal bodies which is made of Cordierite.
The principal element of converter consists of the materials
like Alumina or oxidized Serume in order to apply to Ceramic
Monolith.
Washer coat operates first, and catalytic metal elements (Pt,
Pd, Rh) operates to washer coat next.
Monolith type is lighter than other types, easy to manufacture
and quickly approaches to proper temperature.
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Washer coat is used to make a contact surface with exhaust

gas bigger by adhering closely to small holes of inner layer.
If a lead compound or phosphorus adheres to the surface and
the temperature rises, its surface is decreased.
The total area of general monolith converter is about 45,000 ~
500,000 ft3. (10 times of a football field)
Generally Alumina (AL2 O3) is used as a raw material and its 7
phases of gamma, delta, theta have big areas and high stability for the temperature, and nowadays gamma Alumina is used
usually.
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CATALYTIC CONVERTER AND TEMPERATURE

Catalytic converter has the normal function of purification at a
range of the temperature.
Because it has a weak point of decreasing of the purification
rate in the condition of continuous high temperature, it should
keep the temperature range of 400 to 500C for normal condition.
HC purification rate becomes better according to the increase
of temperature in the normal range of temperature.
CO purification rate becomes the best near the temperature of
450C, and NOx does so near the temperature of 400 to 500C.

M162 GSL ENG SM - 2005.7
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1G-4
PURIFICATION OF CATALYTIC
CONVERTER
Adhesion of soluble organic fraction (SOF) below 180C
Purification of soluble organic fraction (SOF) over 180C
Chemical reaction formula
- SOF(HC)+O2
CO2+H2O
- 2CO+O2
2CO2
- 2C2H6+7O2
4CO2+6H20
By catalytic action of two primary catalytic converter,

oxidation occurs in order to decrease HC and CO.
Oxygen adheres to catalytic material : below 180C
Catalytic material supplies each CO and HC with O2 for

their oxidation : above 180C
Catalytic material conversion process by DOC
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M162 GSL ENG SM - 2005.7
1G-5
Method for Reduction of NOx

NOx is generated a great deal in case that combustion temperature and excess air factor are high. EGR valve can decrease NOx (30 to 35% decrease) by making temperature of
combustion chamber fall by means of exhaust gas recirculation.
EGR valve is installed on the diesel engine of Musso,
Korando, Istana and Rexton.
And micro switch is installed together to control EGR valve.
The setting method of micro switch is identical with the
existing one.
RESONANCE FLAP
Function
A pneumatically actuated resonance flap (5) is located on the
intake manifold, and will be opened and closed by load, which
operates resonance flap according to engine and controlled
by ECU and rpm.
Resonance flap closed (at idle/partial load: less

than 3,800 rpm)
The switch valve (7) will be adjusted by ECU and resonance
falp will be colosed. By increasing air flow passage through
dividing intaking air flow toward both air collection housing (8).
This leads to a signficant increase in the torque in the lower
speed range.
Resonance flap open (at full load: over 3,800 rpm)

The switch valve (7) will not be adjusted by ECU and resonance falp (5) will be open. The collected air in the air collection housing (8) will not be divided and intaking air passage
will be shorten.

M162 GSL ENG SM - 2005.7
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1G-6
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
AIR CLEANER AND INTAKE AIR DUCT
Cover
Element
Housing
Specifications
Element Type
Dry-Element Type
* Initial cleaning: 5,000 km, Clean or change every 10,000 km as required.
However, change every 30,000 km.
Service Interval
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* If the vehicle is operated under severe condition (short distance driving, extensive
idling or driving in dusty condition): More frequent maintenance is required.
M162 GSL ENG SM - 2005.7
1G-7
Air Cleaner Element - Replacement

Preceding Work: Disconnection of negative battery cable
2. Loosen the locking clamp and remove the intake duct.
3. Unscrew the screws and remove the air cleaner cover.
4. Remove the air cleaner element. Clean or replace the

element as required.

M162 GSL ENG SM - 2005.7
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1G-8
Air Cleaner Housing - Removal and

Installation
Preceding Work: Removal of air cleaner cover
1. Set aside the return hose and remove the coolant reservoir
bolts.
2. Remove the air cleaner housing bolts.

3. Install in the reverse order of removal.
Air Cleaner Housing/Element - Check

1. Check the air cleaner body, cover and packing for
deformation, corrosion and damage.
2. Check the air duct for damage.
3. Check the air cleaner element for clogging, contamination

and damage. If the element is partially clogged, remove
the dust or foreign materials with the compressed air. If
the contamination is severe, replace it with new one. Also,
be careful not to contaminate during the replacement.
4. Check the air cleaner housing for clogging, contamination
and damage.
5. If the inside of housing is contaminated, remove the
contaminants.
Notice
When cleaning the air cleaner with compressed air,
direct the air from inside (engine) to outside (ambient
air). Otherwise, contaminants can get into the engine.
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M162 GSL ENG SM - 2005.7
1G-9
INTAKE MANIFOLD
Preceding Work: Removal of fuel rail
Removal of battery
Removal of canister
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Bolt (M6 X 40, 4 pieces) 9 ~ 11 Nm (80 ~ 97 lb-in)

Softcap
Resonance flap
Gasket ....................................................... replace
Upper intake manifold
Bolt (M8 X 50, 9 pieces)
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
Gasket ....................................................... replace
Blow-by hose
Blow-by hose
Clamp
Blow-by nipple
Inlet air housing

M162 GSL ENG SM - 2005.7
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Bolt (M6 X 40, 4 pieces) 9 ~ 11 Nm (80 ~ 97 lb-in)

Throttle body-electric
Gasket ....................................................... replace
Lower intake manifold
Bolt (M8 X 40, 4 pieces)
....................... 22.5 ~ 27.5 Nm (16.6 ~ 20.3 lb-ft)
Nipple
Seal ring
Connector
Connection house
Clamp
Noise damper assembly
Tapping screw
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1G-10
RESONANCE FLAP
1. Soft cap (2)
4. Vacuum hose
2. Bolt (M6 X 40, 4 piecesc)
5. Resonance flap
....................................... 9 ~ 11 Nm (80~ 97 lb-in)
6. Gasket ...................................................... Replace
3. O-ring

1. Remove the 2 soft caps (1).
2. Remove the upper resonance flap coupling after removing
4 bolt (2).
Installation
Tightening torque
9 ~ 11 Nm
(80 ~ 97 lb-ft)
3. Check the O-ring (3) and replace it if necessary.

4. Remove the lower resonance flap (5).
5. Replace the gasket (6).
reverse order.
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M162 GSL ENG SM - 2005.7
1G-11
EXHAUST LINE
1. Front exhaust pipe
9. Heat protector No. 2
2. Muffler
3. Tail exhaust pipe
4. Gasket ....................................................... replace
12. Bolt ............................. 15 ~ 28 Nm (11 ~ 21 lb-ft)
5. Gasket ....................................................... replace
13. Nut .............................. 28 ~ 47 Nm (21 ~ 35 lb-ft)
6. Hanger
14. Nut .................................. 8 ~ 18 Nm (6 ~ 13 lb-ft)
7. Hanger
15. Screw
16. Oxygen sensor

M162 GSL ENG SM - 2005.7
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1G-12

1. Disconnect the oxygen sensor electrical connectors.
2. Remove the exhaust manifold to front exhaust pipe nuts.
Installation Notice
3. Remove the oxygen sensor and hanger from the front
exhaust pipe.
Tightening torque
15 ~ 28 Nm
(11 ~ 21 lb-ft)
4. Remove the front exhaust pipe to muffler nuts.

Installation
Tightening torque
28 ~ 47 Nm
(21 ~ 35 lb-ft)
5. Remove the muffler to tail exhaust pipe nuts.

Installation
Tightening torque
28 ~ 47 Nm
(21 ~ 35 lb-ft)
6. Remove the Mounting hunger and muffler.
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M162 GSL ENG SM - 2005.7
1G-13
7. Remove the mounting hanger and tail exhaust pipe.
8. Check the muffler and pipes for holes, damage, open
seams, or other deterioration. Which could permit
exhaust fumes to seep into the passenger compartment
or the trunk.
reverse order.

M162 GSL ENG SM - 2005.7
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1G-14
SPECIFICATIONS
Application
Nm
Lb-Ft
Lb-In
Exhaust manifold to front exhaust pipe nut
15 ~ 28
11 ~ 21
Front exhaust pipe to muffler nut
28 ~ 47
21 ~ 35
Intake air duct mounting bolt
22.5 ~ 27.5
16.6 ~ 20.3
Intake manifold mounting bolt
22.5 ~ 27.5
16.6 ~ 20.3
Muffler to tail exhaust pipe nut
28 ~ 47
21 ~ 35
Resonance flap mounting bolt
9 ~ 11
80 ~ 97
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M162 GSL ENG SM - 2005.7
DI0A-1
SECTION
00 DI0A
GENERAL INFORMATION
Table of Contents
CLEANNESS ....................................... DI0A-2
STRUCTURE ...................................... DI0A-7
ENGINE CONTROLS ....................... DI0A-10
ECU related components ............. DI0A-10
Engine and sensors ...................... DI0A-11
Electrical components and pre heating
system .......................................... DI0A-12
INTAKE SYSTEM ............................. DI0A-13
Intake air flow chart ...................... DI0A-14
EXHAUST SYSTEM .......................... DI0A-15
STANDARD BOLTS SPECIFICATIONS

.......................................................... DI0A-32
BASIC SPECIFICATION ................... DI0A-34
LUBRICATION SYSTEM .................. DI0A-17
Vehicle specifications ................... DI0A-34

Specifications ............................... DI0A-35
Maintenance ................................ DI0A-37
COOLING SYSTEM ......................... DI0A-18
VEHICLE IDENTIFICATION .............. DI0A-39
Coolant flow chart ........................ DI0A-19
Vehicle identification number (VIN)

..................................................... DI0A-39
Manufacturers plate .................... DI0A-40
Engine serial number ................... DI0A-40
Transmission & transfer case number
..................................................... DI0A-41
Exhaust air flow chart ................... DI0A-16
FUEL SYSTEM ................................. DI0A-20

Fuel supply system ...................... DI0A-21
MAINTENANCE AND REPAIR .......... DI0A-22
Maintenance and lubrication ....... DI0A-22
Guidelines for
service work safety ...................... DI0A-23
Vehicle lifting procedures ............ DI0A-28
OWNER INSPECTIONS AND SERVICES
.......................................................... DI0A-30
GENERAL INFORMATION
DI ENG SM - 2004.9
While operating the vehicle ......... DI0A-30

At each fuel fill ............................. DI0A-30
At least twice a month .................. DI0A-30
At least monthly ........................... DI0A-30
At least twice a year ..................... DI0A-31
Each time the oil is changed ....... DI0A-31
At least annually .......................... DI0A-31
HOW TO USE AND MAINTAIN WORKSHOP

MANUAL ........................................... DI0A-42
Consists of workshop manual ...... DI0A-42
Manual description ...................... DI0A-42
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DI0A-2
CLEANNESS
Cleanness of DI Engine Fuel System and Service Procedures
The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure
reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 m of
preciseness. The pressure regulation and injector operation are done by electric source from engine ECU.
Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the
HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over
250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side
figure shows the clearance between internal operating elements.
Valve actuator lift: 0.028 mm

Hair
Diameter: 0.40 mm
Nozzle hole
Operating
clearance:
0.002 mm
Diameter:
2.0 mm
The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign
material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of
system problems and claims may arise.
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GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-3
Job procedures
1. Always keep the workshop and lift clean (especially, from dust).
2. Always keep the tools clean (from oil or foreign materials).
3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.
Wash your hands and do not wear working gloves.
4. Follow the below procedures before starting service works for fuel system.
Carefully listen the symptoms and problems from customer.
Visually check the leaks and vehicle appearance on the wiring harnesses
and connectors in engine compartment.
Perform the diagnosis proceee with SCAN-100

(refer to DI10 DIAGNOSIS section in this manual).
Locate the fault. If the cause is from fuel system (from priming pump to
injector, including return line), follow the step 1 through step 3 above.
5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing caps
to perform the diagnosis for DI engine fuel system in DI10 DIAGNOSIS section in this manual. At this point,
thoroughly clean the related area in engine compartment.
Notice
Clean the engine compartment before starting service works.
Tool kit for high pressure line
GENERAL INFORMATION
DI ENG SM - 2004.9
Took kit for low pressure line
Removal tool box and cap kits
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DI0A-4
6. Follow the job procedures. If you find a defective component, replace it with new one.
Disconnect the negative battery cable.
For safety reasons: check pressure is low before opening the HP systems (pipes)
Use special tools and torque wrench to perform the correct works.
Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail
and each injector should be replaced with new ones. The pipes should be tightened to
specified tightening torques during installation. Over or under torques out of specified
range may cause damages and leaks at connections. Once installed, the pipes have been
deformed according to the force during installtion, therefore they are not reusable.
The copper washer on injector should be replaced with new one. The injector holder bolt
should be tightened to specified tightening torque as well. If not, the injection point may be
deviated from correct position, and it may cause engine disorder.
Plug the disconnected parts with sealing caps, and remove the caps immediately
before replacing the components.
Fuel pressure sensor
High pressure pump
Common rail
IMV valve
Injection
pipe
Transfer pump and high

pressure pump
Fuel temperature sensor
Water separator
Water detection sensor
Priming
pump
Fuel filter
Injector
Cap position
Supply line
Return line
Fuel tank
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GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-5
7. Plug the removed components with clean and

undamaged sealing caps and store it into the box to
keep the conditions when it was installed.
8. Clear the high pressure offset value by SCAN-100 after
replacing the high pressure pump.
9. To supply the fuel to transfer line of HP pump press

the priming pump until it becomes hard.
Warning
Do not crank engine before having filled pump.

Priming pump
10. Check the installed components again and connect

the negative battery cable. Start the engine and check
the operating status.
11. With SCAN-100, check if there are current faults and
erase the history faults.
Note
For details, refer to DI10 Diagnosis table.
GENERAL INFORMATION
DI ENG SM - 2004.9
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DI0A-7
STRUCTURE
Front view
Rear view
1. TVD (Torsional Vibration Damper)
7. Viscos clutch
13. Oil filter
2. Air conditioner compressor
8. Auto tensioner pulley
14. Vacuum pump
9. Auto tensioner
15. Crank position sensor
10. Poly-groove belt
16. EGR valve
11. Cam position sensor
6. Alternator
12. Drive plate (M/T: DMF)
18. EGR center pipe
4. Idle pulley
GENERAL INFORMATION
DI ENG SM - 2004.9
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AFFECTED VIN
DI0A-8
Top view
24. Fuel pipe
29. Booster pressure sensor
20. Intake manifold
25. Injector
30. Oil separator
21. Water outlet port
26. Fuel return line
31. Oil dipstic
22. Common rail
27. Oil filler cap
32. EGR center pipe
23. Fuel pressure sensor
28. Glow plug
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GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-9
Left side view
Right side view
42. Turbo charger booster vacuum
33. Cylinder head
38. EGR - RH pipe
34. Cylinder block
39. Oil separator
35. Oil pan
40. Oil dipstic
43. EGR valve vacuum modulator
36. Drain plug
41. HP pump
44. EGR valve
37. Turbo charger
GENERAL INFORMATION
DI ENG SM - 2004.9
modulator
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AFFECTED VIN
DI0A-10
ENGINE CONTROLS
ECU RELATED COMPONENTS
ECU/barometric sensor
Cam position sensor
HFM sensor/intake air

temperature sensor
CHANGED BY
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AFFECTED VIN
Fuel filter
(water detection sensor)
Pre heating time relay
Accelerator pedal sensor
Main relay
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-11
ENGINE AND SENSORS

Injector
Crankshaft position
sensor
Glow plug
Camshaft position
sensor
Booster pressure sensor
HP pump
GENERAL INFORMATION
DI ENG SM - 2004.9
Common rail
Coolant temperature
sensor
Knock sensor (2)
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DI0A-12
ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM

Glow plug
Pre heating time relay
Battery
Fuse box
Alternator
Starter motor
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-13
INTAKE SYSTEM
Air cleaner assembly
HFM sensor
Intake duct hose
Intake manifold
Intake outlet hose
Turbocharger
Intercooler
Inlet hose
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-14
INTAKE AIR FLOW CHART
Intake valve (in combustion chamber)
Intake manifold
Air cleaner side
Turbocharger
(compressor)
Engine
HFM sensor
Intake hose (outlet)
CHANGED BY
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AFFECTED VIN
Intercooler
Intake hose (inner)
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-15
EXHAUST SYSTEM
Muffler
Turbocharger
GENERAL INFORMATION
DI ENG SM - 2004.9
Catalytic converter
Exhaust manifold
EGR valve
EGR pipe
Vacuum modulator
CHANGED BY
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AFFECTED VIN
DI0A-16
EXHAUST AIR FLOW CHART
Catalytic converter
Exhaust pipe
Muffler
Ambient
air
Exhaust gas
Turbocharger
(turbine side)
EGR vacuum
modulator
To turbocharger
booster
Turbocharger
booster vacuum
modulator
Turbocharger booster
EGR valve
Exhaust manifold
EGR pipe
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-17
LUBRICATION SYSTEM
Cylinder head cover
Oil dipstick
Oil separator
Engine oil filter

housing
Engine oil pump
Oil pan
Engine oil cooler
Engine oil pressure

switch
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-18
COOLING SYSTEM
CHANGED BY
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AFFECTED VIN
Coolant reservoir
Water pump
Radiator assembly
Cooling fan and fan

clutch
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-19
COOLANT FLOW CHART

Heater
Oil cooler
Coolant reservoir
Intake manifold
Thermostat
Coolant outlet port
Water pump
Inner hose
Outlet hose
Cooling fan
Radiator
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-20
FUEL SYSTEM
Fuel return hose
Injector
CHANGED BY
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AFFECTED VIN
Fuel pressure pipe
HP pump
Common rail
Fuel filter
Priming pump
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-21
FUEL SUPPLY SYSTEM

High pressure pump
Common rail
IMV valve
High
pressure
pipe
Low and high

pressure pump
Fuel temperature
sensor
Water separator
Fuel filter
Label
(C2I)
Priming pump
Water detection
sensor
Injector
Sensors
HFM sensor
Cam position sensor
ECU
Fuel tank
Crank position sensor

Knock sensor etc.
Components:
- High pressure fuel pump
- Fuel rail
- Fuel pressure sensor
- Fuel injectors
- Electroc control unit (ECU)
- Various sensors and actuators
Supply line
Return line
ECU communication line
According to input signals from various sensors, engine ECU calculates drivers demand (position of the accelerator
pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects drivers pedal position (drivers demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and
sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume
changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from
coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI0A-22
MAINTENANCE AND REPAIR

MAINTENANCE AND LUBRICATION
Normal Vehicle Use
The maintenance instructions contained in the maintenance
schedule are based on the assumption that the vehicle
will be used for the following reasons:
To carry passengers and cargo within the limitation of
the tire inflation prassure. Refer to Wheels and Tire
in section 4H.
To be driven on reasonable road surfaces and within
legal operating limits.
Explanation of Scheduled
Maintenance Services
The services listed in the maintenance schedule are further explained below. When the following maintenance
services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants.
Engine Oil and Oil Filter Change

Always use above the API SH grade or recommended engine oil.
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel
economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold weather
performance; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory
lubrication. Using oils of any viscosity other than those
viscosities recommended could result in engine damage.
Fuel Filter Replacement

Replace the engine fuel filter every.
Gasoline Engine : 60,000 km (36,000 miles)
Diesel Engine : 30,000 km (18,000 miles)
Spark Plug Replacement

Replace spark plugs with same type.
Type : BOSCH : F8DC4
BERU : 14F-8DU4
Champion : C11YCC
Gap : 0.8 0.1 mm
Spark Plug Wire Replacement

Clean wires and inspect them for burns, cracks or other
damage. Check the wire boot fit at the Distributor and at
the spark plugs. Replace the wires as needed.
Brake System Service
Check the disc brake pads or the drum brake linings. Check
the pad and the lining thickness carefully.
Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize
wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and
wheels are removed, inspect the brakes.
Tire Rotation (Left-hand Drive Type)
Cooling System Service

Drain, flush and refill the system with new coolant. Refer
to Recommended Fluids And Lubricants in this section.
Air Cleaner Element Replacement
Clean the air cleaner element every.
Replace the air cleaner element every.
Replace the air cleaner more often under dusty conditions.
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AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-23
GUIDELINES FOR SERVICE WORK SAFETY

General
Cautions on Inspection/Service
Notice
During service works, be sure to observe below general

items for your safety.
For service works, be sure to disconnect battery
negative (-) terminal if not starting and inspection.
While inspecting vehicle and replacing various
consumable parts, be sure to take caution not to
damage vehicle and injure people.
Engine and transmission may be hot enough to
burn you. So inspect related locations when they
cooled down enough.
To maintain and operate the vehicle under optimum state
by performing safe service works, the service works should
be done by following correct methods and procedures.
Accordingly, the purpose of this manual is to prevent differences that can be caused by personal working method,
skill, ways and service procedures and to allow prompt/
correct service works.
Note, Notice
While using this manual, there are a lot of Note or Notice
having below meaning.
Note
Note means detailed description of supplementary

information on work procedure or skill.
Notice
Notice means precautions on tool/device or part

damages or personal injuries that can occur during
service works.
However, above references and cautions cannot be inclusive measures, so should have habits of taking concerns
and cautions based on common senses.
If engine is running, keep your clothing, tools, hair

and hands away from moving parts.
Even when the ignition key is turned off and
positioned to LOCK, electrical fan can be operated
while working on near around electrical fan or
radiator grille if air conditioner or coolant
temperature rises.
Every oil can cause skin trouble. Immediately wash
out with soap if contacted.
Painted surface of the body can be damaged if
spilled over with oil or anti-freeze.
Never go under vehicle if supported only with jack.
Never near the battery and fuel related system to
flames that can cause fire like cigarette.
Never disconnect or connect battery terminal or other
electrical equipment if ignition key is turned on.
While connecting the battery terminals, be cautious
of polarities (+, ) not to be confused.
There are high voltage and currency on the battery
and vehicle wires. So there can be fire if shortcircuited.
Do not park while running the engine in an
enclosed area like garage. There can be toxication
with CO, so make sufficient ventilation.
The electrical fan works electrically. So the fan can
be operated unexpectedly during working causing
injuries if the ignition key is not in LOCK position.
Be sure to check whether ignition key is in LOCK
position before work.
Be careful not to touch hot components like
catalytic converter, muffler and exhaust pipe when
the engine is running or just stopped. They may
burn you badly.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-24
Guidelines on Engine Service

To prevent personal injuries and vehicle damages that can
be caused by mistakes during engine and unit inspection/
repair and to secure optimum engine performance and
safety after service works, basic cautions and service work
guidelines that can be easily forgotten during engine service works are described in.
Fuel and lubrication system

Painted surface of the body can be damaged or rubber
products (hoes) can be corroded if engine oil and fuel are
spilled over. If spilled over engine, foreign materials in air
can be accumulated on the engine damaging fuel system.
If work on the fluid system such as fuel and oil, working
area should be well ventilated and mechanic should
not smoke.
Cautions before service works

Before work on engine and each electrical equipment,
be sure to disconnect battery negative (-) terminal.
Gasket or seal on the fuel/lubrication system should

be replaced with new and bolts and nuts should be
tightened as specified.
Before service works, be sure to prepare the works by

cleaning and aligning work areas.
After removal/installation works, be sure to check

whether there is leak on the connecting section.
Always position the ignition switch to OFF if not

required. If not, there can be electrical equipment
damages or personal injuries due to short-circuit or
ground by mistake.
There should be no leak from fuel injection system
(HP pump, fuel hose, high pressure pipe) of the D27DT
engine. So they should be protected from foreign
materials.
While removing the engine, do not position the jack
and others under the oil pan or engine. To secure the
safety, use only safety hook on the engine.
Engine and accessories

Engine has a lot of precise portions so tightening torque
should be correct during disassembly/assembly and removal/installation and service work should be done in clean
ways during disassembly/assembly.
Maintaining working area clean and cautious service administration is essential element of service works while
working on the engine and each section of the vehicle. So
the mechanics should well aware of it.
While removing the engine, related parts (bolts,
gaskets, etc.) should be aligned as a group.
While disassembling/assembling internal components
of the engine, well aware of disassembly/assembly
section in this manual and clean each component with
engine oil and then coat with oil before installation.
If fine dust or foreign material enters into DI engines

fuel system, there can be serious damages between
HP pump and injectors. So, be sure to cover removed
fuel system components with cap and protect removed
parts not to be contaminated with dirt. (Refer to cleanness in this manual while working on DI engine fuel
system)
Electrical equipment
Electrical equipment should be handled more carefully.
Currently, the engine is equipped with a lot of electrical
equipments so there can be engine performance drops,
incomplete combustion and other abnormals due to short
and poor contact. Mechanics should well aware of vehicles
electrical equipment.
If have to work on the electrical equipment, be sure to
disconnect battery negative (-) terminal and position
the ignition switch to off if not required.
When replacing electrical equipment, use the same
genuine part and be sure to check whether ground or
connecting portions are correctly connected during
installation. If ground or connecting portion is loosened,
there can be vehicle fire or personal injury.
While removing engine, drain engine oil, coolant and

fuel in fuel system to prevent leakage.
During service work of removal/installation, be sure to
check each connected portions to engine not to make
interference.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-25
During Service Work - Inspection

1. Before lifting up the vehicle with lift, correctly support the
lifting points and lift up.
2. When using a jack, park the vehicle on the level ground
and block front and rear wheels. Position the jack under
the frame and lift up the vehicle and then support with
chassis stand before service work.
3. Before service work, be sure to disconnect battery

negative (-) terminal to prevent damages by bad wire and
short.
4. If service from interior of the vehicle, use protection cover

to prevent damage and contamination of seat and floor.
5. Brake fluid and anti-freeze can damage painted surface
of body. So carefully handle them during service work.
6. Use recommended and specified tools to increase

efficiency of service work.
7. Use only genuine spare parts.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-26
8. Never reuse cotter pin, gasket, O-ring, oil seal, lock
washer and self-locking nut. Replace them with new.
If reused, normal functions cannot be maintained.
9. Align the disassembled parts in clean according to
disassembling order and group for easy assembling.
10. According to installing positions, the bolts and nuts have
different hardness and design. So be careful not to mix
removed bolts and nuts each other and align them
according installing positions.
11. To inspect and assemble, clean the parts.
12. Securely clean the parts that related with oil not to be
affected by viscosity of oil.
13. Coat oil or grease on the driving and sliding surfaces
before installing parts.
14. Use sealer or gasket to prevent leakage if necessary.
15. Damaged or not, never reuse removed gasket. Replace
with new and cautious on installing directions.
16. Tighten every bolt and nut with specified torque.
17. When service work is completed, check finally whether
the work is performed properly or the problem is solved.
18. If work on the fuel line between priming pump and injector
(including return line), be sure to cover the removed parts
with cap and be careful not to expose the connecting
passage and removed parts to external foreign materials
or dust. (Refer to cleanness.)
19. If remove high pressure fuel supply pipe between HP pump
and fuel rail and high pressure fuel pipe between fuel rail
and each injector, be sure to replace them with new.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-27
During Service Work for Electric

Devices
Notice
Be careful not to modify or alter electrical system and

electrical device. Or there can be vehicle fire or serious
damage.
1. Be sure to disconnect battery negative (-) terminal during
every service work. Before disconnecting battery negative
(-) terminal, turn off ignition key.
2. Replace with specified capacity of fuse if there is bad,
blown or short circuited fuse. If use electrical wire or steel
wire other than fuse, there can be damages on the various
electrical systems. If replaced with over-capacity fuse,
there can be damages on the related electrical device
and fire.
3. Every wire on the vehicle should be fastened securely
not to be loosened with fixing clip.
4. If wires go through edges, protect them with tape or other
materials not to be damaged.
5. Carefully install the wires not to be damaged during

installation/removal of parts due to interference.
6. Be careful not to throw or drop each sensor or relay.
7. Securely connect each connector until hear a click
sound.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-28
VEHICLE LIFTING PROCEDURES

To raise the vehicle, place the lifting equipment only at the
points indicated. Failure to use these precise positions
may result in permanent vehicle body deformation.
Many dealer service facilities and service stations are
equipped with automative hoists that bear upon some parts
of the frame in order to lift the vehicle. If any other hoist
method is used, take special care to avoid damaging the
fuel tank, the filter neck, the exhaust system, or the
underbody.
Using Floor Jack

Front Side
Rear Side
Using Jack
Front Jack Up Point
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear Jack Up Point
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-29
Lifting Positions
1. 4-post lift
As illustrated, position the vehicle on the 4-post lift securely and block the front and rear of each tire not to move during
working.
Notice
During lifting, be sure to check whether vehicle is empty.

Board-on lift connection device installed in front of vehicle should be positioned in front of sill locating
under the front door.
Install lift connecting device on the edge of front and rear of board-on lift.
Warning
Be sure to use attachment during lifting to prevent the lift from contacting with body floor.
While lifting the vehicle, widen the lift floor as far as possible to stabilize between vehicle front and rear. When
fixing the lift floor, be careful not to contact with brake tube and fuel lines.
2. Safety jack and safety stand

If lift up the vehicle with safety jack and stand, should be more
careful during works.
Warning
Never be under the vehicle if supported with only jack.
If have to be under the vehicle, be sure to use safety
block.
Use wheel block in front and rear of every wheel.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-30
OWNER INSPECTIONS AND SERVICES

WHILE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally to make sure it works. Check
all the button locations.
4. Pull out the oil level indicator and look at the oil level
on it.
Brake System Operation

Be alert for abnormal sounds, increased brake pedal travel
or repeated puling to one side when braking. Also, if the
brake warning light goes on, or flashes, something may
be wrong with part of the brake system.
6. Push the indicator all the way back down into the
engine after taking the reading.
Exhaust System Operation

Be alert to any changes in the sound of the system or the
smell of the fumes. These are signs that the system may
be leaking or overheating. Have the system in-spected and
repaired immediately.
Tires, Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats
at normal highway speeds. This may mean a wheel needs
to be balanced. Also, a pull right or left on a straight, level
road may show the need for a tire pressure adjustment or
a wheel alignment.
5. Add oil, if needed, to keep the oil level above the

lower mark. Avoid overfilling the engine, since this
may cause engine damage.
If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the pan
fast enough to give a true oil level reading.
Engine Coolant Level and Condition

Check the coolant level in the coolant reservoir tank and
add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST TWICE A MONTH
Steering System Operation

Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or has
too much free play, or is unusual sounds are noticed when
turning or parking.
Tire And Wheel Inspection and Pressure Check

Check the tire for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold (check the spare also, unless it is a stowaway).
Headlamp Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.
Maintain the recommended pressures. Refer to Wheels

and Tire is in section 4H.
AT LEAST MONTHLY
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may
indicate a problem. Have the system inspected and repaired immediately.
Engine Oil Level

Check the oil level and add oil if necessary. The best time
to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for the
oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Lamp Operation
Check the operation of the license plate lamp, the headlamps (including the high beams), the parking lamps, the
fog lamps, the taillamp, the brake lamps, the turn signals,
the backup lamps and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning
system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-31
AT LEAST TWICE A YEAR

Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power steering
fluid at the proper level. Refer to Section 4G, Power Steering
System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid level
can indicate worn disc brake pads which may need to be
serviced. Check the breather hole in the reservoir cover to be
free from dirt and check for an open passage.
Weather-Strip Lubrication
Apply a thin film silicone grease using a clean cloth.
EACH TIME THE OIL IS CHANGED
Hood Latch Operation

When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all
the way when the primary latch is released. The hood
must close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops
and the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Brake System Inspection

This inspection should be done when the wheels are removed
for rotation. Inspect the lines and the hoses for proper hookup,
binding, leaks, cracks, chafing, etc. Inspect the disc brake
pads for wear. Inspect the rotors for surface condition. Inspect
other brake parts, the parking brake, etc., at the same time.
Inspect the brakes more often if habit or conditions result in
frequent braking.
Spare Tire and Jack Storage

Be alert to rattles in the rear of the vehicle. The spare
tire, all the jacking equipment, and the tools must be
securely stowed at all times. Oil the jack ratchet or
the screw mechanism after each use.
Steering, Suspension and Front Drive Axle Boot

And Seal Inspection
Inspect the front and rear suspension and the steering system for damaged, loose or missing parts, signs of wear or
lack of lubrication. Inspect the power steering line and the
hoses for proper hookup, binding, leaks, cracks, chafing, etc.
Clean and inspect the drive axle boot and seals for damage,
tears or leakage. Replace the seals if necessary.
Body Lubrication Service

Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the
latches, the glove box and the console doors, and any
folding seat hardware.
Exhaust System Inspection

Inspect the complete system (including the catalytic converter
if equipped). Inspect the body near the exhaust system. Look
for broken, damaged, missing, or out-of-position parts as well
as open seams, holes, loose connections, or other conditions
which could cause heat buildup in the floor pan or could let
exhaust fumes seep into the trunk or passenger compartment.
Drain the Water from Fuel Filter
When the water level inside water separator in fuel filter exceeds a certain level, water separator warning light comes on
and buzzer sounds. Also, the driving force of the vehicle
decreases.
If these conditions occur, immediately drain the water from
fuel filter & water separator.
GENERAL INFORMATION
DI ENG SM - 2004.9
Key Lock Service

Lubricate the key lock cylinder.
Underbody Flushing
Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control.
At least every spring clean the underbody. First, loosen
the sediment packed in closed areas of the vehicle.
Then flush the underbody with plain water.
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the
fluid is dirty or rusty, drain, flush and refill the engine
cooling system with new coolant. Keep the coolant at
the proper mixture in order to ensure proper freeze
protection, corrosion protection and engine operating
temperature. Inspect the hoses. Replace the cracked,
swollen, or deteriorated hoses. Tighten the clamps.
Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to
help ensure proper operation.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-32
STANDARD BOLTS SPECIFICATIONS

Torque (Nm / Ib-in)
Standard
Bolt*
M3 0.5
M4 0.7
M5 0.8
M6 1.0
M8 1.25
M10 1.25
M10 1.5
M12 1.25
M12 1.75
M14 1.5
M16 1.5
M18 1.5
M20 1.5
M22 0.5
M24 1.5
M24 2.0
Limit
9T
4T
0.5 Nm
7T
0.9 Nm
9T
1.3 Nm
4T
0.7 Nm
7T
1.2 Nm
17 Nm
(4.5 lb-in)
(8 lb-in)
(12 lb-in)
(6.3 lb-in)
(11 lb-in)
(15 lb-in)
1.2 Nm
2.0 Nm
3.0 Nm
1.6 Nm
2.6 Nm
4.0 Nm
(11 lb-in)
(18 lb-in)
(27 lb-in)
(14 lb-in)
(23 lb-in)
(36 lb-in)
2.4 Nm
4.0 Nm
5.6 Nm
3.1 Nm
5.2 Nm
7.6 Nm
(22 lb-in)
(36 lb-in)
(50 lb-in)
(28 lb-in)
(47 lb-in)
(68 lb-in)
4.0 Nm
6.7 Nm
9.7 Nm
5.4 Nm
9.0 Nm
12.7 Nm
(36 lb-in)
(60 lb-in)
(87 lb-in)
(49 lb-in)
(81 lb-in)
(114 lb-in)
8.6 Nm
15.7 Nm
22.5 Nm
12.7 Nm
20.6 Nm
30.4 Nm
(77 lb-in)
(12 lb-in)
(17 lb-in)
(9 lb-in)
(15.2 lb-in)
(22 lb-in)
18.6 Nm
32.3 Nm
46.0 Nm
25.5 Nm
42.1 Nm
60.8 Nm
(14 lb-in)
(24 lb-in)
(34 lb-in)
(19 lb-in)
(31 lb-in)
(31 lb-in)
18.6 Nm
30.4 Nm
44.1 Nm
24.5 Nm
41.2 Nm
58.8 Nm
(14 lb-in)
(22 lb-in)
(33 lb-in)
(18 lb-in)
(30 lb-in)
(44 lb-in)
34.3 Nm
56.8 Nm
82.3 Nm
45.0 Nm
75.5 Nm
107.8 Nm
(25 lb-in)
(42 lb-in)
(61 lb-in)
(33 lb-in)
(56 lb-in)
(80 lb-in)
32.3 Nm
53.9 Nm
77.4 Nm
43.1 Nm
71.5 Nm
98.0 Nm
(24 lb-in)
(40 lb-in)
(57 lb-in)
(32 lb-in)
(53 lb-in)
(73 lb-in)
54.0 Nm
89.2 Nm
127.4 Nm
71.6 Nm
117.6 Nm
166.6 Nm
(40 lb-in)
(66 lb-in)
(94 lb-in)
(53 lb-in)
(87 lb-in)
(123 lb-in)
81.3 Nm
107.8 Nm
196.0 Nm
107.8 Nm
186.2 Nm
264.6 Nm
(60 lb-in)
(80 lb-in)
(145 lb-in)
(80 lb-in)
(138 lb-in)
(196 lb-in)
117.6 Nm
196.0 Nm
284.2 Nm
156.8 Nm
264.6 Nm
372.4 Nm
(87 lb-in)
(145 lb-in)
(210 lb-in)
(116 lb-in)
(196 lb-in)
(276 lb-in)
166.6Nm
274.4 Nm
392.0 Nm
215.6 Nm
362.6 Nm
519.4 Nm
(123 lb-in)
(203 lb-in)
(290 lb-in)
(160 lb-in)
(268 lb-in)
(384 lb-in)
225.4Nm
372.4 Nm
529.2 Nm
294.0 Nm
490.0 Nm
705.6 Nm
(167 lb-in)
(276 lb-in)
(392 lb-in)
(218 lb-in)
(362 lb-in)
(522 lb-in)
284.2 Nm
480.2 Nm
686.0 Nm
382.2 Nm
637.0 Nm
921.2 Nm
(210 lb-in)
(355 lb-in)
(508 lb-in)
(283 lb-in)
(471 lb-in)
(682 lb-in)
274.4 Nm
460.6 Nm
666.4 Nm
372.4 Nm
617.4 Nm
891.8 Nm
(203 lb-in)
(341 lb-in)
(493 lb-in)
(276 lb-in)
(457 lb-in)
(660 lb-in)
*Diameter X pitch in millimeters
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-33
1. Metric bolt strength is embossed on the head of each

bolt. The strength of bolt can be classified as 4T, 7T,
8.8T, 10.9T, 11T and 12.9T in general.
2. Observe standard tightening torque during bolt
tightening works and can adjust torque to be proper
within 15 % if necessary. Try not to over max.
allowable tightening torque if not required to do so.
GENERAL INFORMATION
DI ENG SM - 2004.9
3. Determine extra proper tightening torque if tightens

with washer or packing.
4. If tightens bolts on the below materials, be sure to
determine the proper torque.
Aluminum alloy: Tighten to 80 % of above torque
table.
Plastics: Tighten to 20 % of above torque table.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-34
BASIC SPECIFICATION
VEHICLE SPECIFICATIONS
Vehicle Dimension
(mm)
) : Optional item
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-35
SPECIFICATIONS
Systems
General
Items
Diesel (XDi)
Remark
Overall length (mm)
5,125 (5,220)
Overall width (mm)
1,915 (1,930)
( ): optional
item
Overall height (mm)
1,820 (1,845)
Gross vehicle weight (kg)
2,750 (2,850)
Curb weight (kg)
Engine
AT: 2,134 (2,244), MT: 2,106 (2,217)
Min. turning radius (m)
5.6
Ground clearance (mm)
200
Fuel
Diesel
Fuel tank capacity
80
Model
D27DT
No. of cyl./Compression ratio
5/18:1
2,696 cc
Total displacement
DOHC
Camshaft arrangement
Max. power
170 ps/4,000 rpm
Max. torque
34.7 kgm/1,800 rpm
Injection timing
ATDC 4 1(at idle)

750 20 rpm
Idle speed
Water-cooled/forced circulation
Cooling system
Approx. 11.5
Coolant capacity
Gear pump, forced circulation
Lubrication
9.3
Max. oil capacity

Turbo charger and cooling type
Manual
transmission
Remote control, floor change type
Type
Gear ratio
1st
4.315
2nd
2.475
rd
1.536
th
1.000
5th
0.807
Rev.
3.591
GENERAL INFORMATION
DI ENG SM - 2004.9
Turbo charger, air-cooled
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-36
SPECIFICATIONS (Contd)
Systems
Automatic
transmission
Items
Diesel (XDi)
Model
Electronic
Type
Floor change type

1
2.742
3.595
2.742
2nd
1.508
2.186
1.508
3rd
1.000
1.405
1.000
th
0.708
1.000
0.708
th
0.831
Rev. 1st
2.429
3.162
2.429
Rev. 2nd
1.926
Model
TOD
Type
Gear ratio
Clutch
( ): optional item
st
Gear ratio
Transfercase
Remark
Planetary gear type

High
1.000 : 1
Low
2.483 : 1
Type
Hydraulic [A/T: Torque converter]
Disc type
Dry single diaphragm type

[A/T: 3 elements 1 stage 2 phases]
Power
steering
Front axle
Rear axle
Brake
Type
Steering angle
Rack and pinion

Inner
36 17'
Outer
32 40'
Drive shaft type
Ball joint type
Axle housing type
Build-up type
Drive shaft type
Semi-floating type
Axle housing type
Build-up type
Master cylinder type
Tandem type
Booster type
Type
Vacuum booster
Inner
Disc
Outer
Drum (Disc)
Parking brake
Suspension
Front
Wishbone + Coil spring
Rear
5-link + Coil spring
Air
conditioner
Refrigerant
Electrical
Battery type/Capacity (V-AH)
Alternator capacity (V-A)
CHANGED BY
AFFECTED VIN
R134a
Compressor type
Starter capacity (V-kW)
EFFECTIVE DATE
Cable type (internal expansion)
Vane type
MF / 12 - 90
Diesel : 12 - 2.2, Gasoline : 12 - 1.8
Diesel
12 - 140 (12 - 115)
Gasoline
12 - 115
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-37
MAINTENANCE
Major Components and Service Interval
* Use only Ssangyong Genuine Parts.
Components
Engine
oil and
oil filter
Daily Weekly
Gasoline
engine
DI diesel
engine
Service Interval
Initial change: 10,000 km
Replace at every 15,000 km
Initial change: 5,000 km

Replace at every 10,000 km or 12 months
Coolant
Replace at every 60,000 km or 3 years
Brake / Clutch fluid
Change every 2 years (Inspect frequently)
Brake pipe and hose
Initial inspection: 1,000 km
Remarks
More frequent maintenance is required if
the vehicle is operated under severe
condition.
Severe conditions?
- Frequent low-speed operation as in
stop-and-go traffic
- When most trips are less than 6 km (in
winter, less than 16 km)
- Driving in sandy, dusty, and salty road
- Driving in mountainous areas
- Extensive idling or high load operation
such as towing a trailer
Inspect at every 20,000 km or 1 year, replace if necessary

-
Inspect at every 10,000 km, adjust or replace if necessary
Gasoline
engine
Clean at every 15,000 km,
DI diesel
engine
Brake pad, shoe and

disc
Air
cleaner
element

-
Clean at every 10,000 km, replace if

necessary,
If vehicle is operated under dusty or sandy

area, frequently clean and inspect the air
cleaner system. If necessary, replace the air
cleaner element.

Fuel filter Gasoline
engine
DI diesel
engine
Replace at every 30,000 km (Drain the water from fuel filter at every 10,000 km)
Automatic transmission oil
Manual transmission
oil
Inspect at every 10,000 km,
Transfer case oil
More frequent maintenance is required if the

vehicle is operated under severe condition.
- Driving in unpaved road
- Towing a trailer

-
Inspect at every 10,000 km,

Replace at every 60,000 km (but, frequently check the leaks)
Axle oil
Air conditioner air

filter
Spark plug
(gasoline engine)
Water separator
(DI diesel engine)
Replace at 150,000 km or every 5 years. Only vehicle with water separator.

(Drain the water at every 10,000 km)
GENERAL INFORMATION
DI ENG SM - 2004.9
More frequent maintenance is required if the

vehicle is operated under severe condition.
- Driving in sandy, dusty, and unpaved road
- Excessive operation of air conditioner or
heater
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-38
Lubrication Chart
Lubricant
Capacity
Classification
Quality
class**
DI Diesel
6.8 ~ 8.3 L
(DI: Direct Injection)
Quality
class**
7.0 ~ 9.0 L
Gasoline
DI Engine
API : SJ grade or above,

ACEA : A2 or A3
MB sheet No. 224.1
MB sheet 325.0,
BASF GLYSANTIN G05-11,
Gasoline
11.3 ~ 11.5 L
4WD: 3.6 L, 2WD: 3.4 L
Manual transmission oil

Brake/Clutch fluid (Level must be
maintained between MAX & MIN
level)
Properly
HOECHST GENANTIN SUPER 8023/14

ATF DEXRON II, III
DOT 4
Power steering fluid
1.1 L
ATF DEXRON II, III
Automatic transmission fluid
8.0 L
SHELL or FUCHS ATF 3353
Transfer case fluid
1.4 L
API GL-5 or SAE 80W/90 (Viscosity grade)
Axle fluid
11.0 ~ 12.0 L
MB sheet No. 224.1
MB sheet : 229.1/3 (preferable)

Viscosity
Engine coolant
(Antifreeze and soft water mixed***)
ACEA : B2, B3 or B4
MB sheet : 229.1/3 (preferable)
Viscosity
Engine oil
API : CG grade or above,
Front
1.3 ~ 1.4 L
Rear
1.7 L
SAE 80W/90, API GL-5
Wheel bearing grease
Properly
SHELL Retinax A grade
Propeller shaft grease - Front/Rear
Properly
ALVANIA EP#2
Please contact Ssangyong Dealer for approved alternative fluid.
** In only case not available MB 229.1 or 229.3, API or ACEA oil may be accepted, however it would rather recommend
to shorten the change interval around 30%.
*** Mixture of antifreeze to water (demineralized)
- General region ; 50 % : 50 %
- Extremily coil region ; 60 % : 40 %
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-39
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (VIN)
Vehicle identification number (VIN) is is on the right front
axle upper frame.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 0
* K P T N 0 B 1 9 S Y P 0 0 0 0 0 0 *
Digit
0
: Symbol according to no. 3. 1. 2 sentence 4 of

76/114/EEC
: Nation - K
: Maker identification - P
: Vehicle type
T - Passenger car
: Line & Models

N: STAVIC or RODIUS (LHD), V: STAVIC or RODIUS (RHD)
: 0: 5 Door, 1: 4 Door, 2: 3 Door
: A - Standard, B - Deluxe, C - Super Deluxe
: Restraint system
1 - 3 points Safety Belt, 2 - 2 points Safety Belt
: Engine type
6 - 2295cc, In-line 4 cylinders, Gasoline (E23)

F - 2696cc, In-line 5 cylinders, Diesel (D27DT)
: Check digit
S - All area except North America
10
: Model year
4 - 2004
5 - 2005
6 - 2006
7 - 2007
8 - 2008
11
: Plant code
P - Pyungtaek plant
12 ~ 17 : Production Serial Number 000001 ~ 999999
Certification Label
The certification label is affixed on the bottom of drivers side
B-pillar.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-40
MANUFACTURERS PLATE
1. Type Approval No.
2. Vehicle Identification No.
ENGINE SERIAL NUMBER

Diesel Engine (D27DT)
The engine number is stamped on the lower area of cylinder
block behind the compressor.
Gasoline Engine (3.2L DOHC)

The engine number is stamped on the lower rear side of
the alternator.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
GENERAL INFORMATION
DI ENG SM - 2004.9
DI0A-41
TRANSMISSION & TRANSFER CASE

NUMBER
Manual
The transmission label is affixed on the upper area of clutch
housing.
Automatic
The transmisson label is affixed on the right area of transmission housing.
Transfer Case
The transfer case label is affixed on the transfer case housing.
GENERAL INFORMATION
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI0A-42
HOW TO USE AND MAINTAIN WORKSHOP MANUAL

CONSISTS OF WORKSHOP
MANUAL
Consists of Small Group
1. Group: The manual is divided in large group like

engine, transmission, axle and others and this group
is also divided in small group by vehicle state.
2. Small group: Each small group consists of general,
vehicle service, unit repair and special tool usage.
MANUAL DESCRIPTION
The contents of the manual consist of operational
principle of system, specifications, diagnosis, removal/
installation on vehicle, inspections, disassembly/
assembly of removed assembly, special tool usage.
Not providing simple removal/installation information
but focused on to describe much more functions, roles
and principles of system.
Every automotive term like part name on the manual
is the same in parts catalog, technical bulletin and
drawings to avoid confusion among them.
Abbreviation of small
group and page
1. Contents: In small group, included subjects and

detailed subjects are described in.
2. General: In the general, summary of the small group
(assembly), function and operational principle,
specifications, structure and components, diagnosis
and circuit diagram are described in.
3. Vehicle service: Service works on the vehicle like
replacement of parts and inspection repairs are
described in the order of repair works with actual
photos and illustrations. Also cautions in service
works, references and inspection methods after
completion of service are described in.
4. Disassembly and assembly of unit assembly:
Detailed service works like disassembly, inspection,
adjustment and assembly on removed component
(assembly) are described in with systematic contents
and photo illustration.
Vehicle model
Bolded: Notice, Installation Notice,

Note
Describes information on the manual

like modification, application date,
applicable V.I.N
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Describes small group name, model

and publication date
GENERAL INFORMATION
DI ENG SM - 2004.9
DI01-1
SECTION
00 DI01
ENGINE ASSEMBLY
Table of Contents
STRUCTURE AND FUNCTION DESCRIPTIONS ........ DI01-2
D27DT engine ........................................................ DI01-2
Engine performance curve ..................................... DI01-7
General diagnosis ................................................... DI01-9
DIAGNOSTIC INFORMATION AND PROCEDURE .. DI01-14
Oil leak diagnosis .................................................. DI01-14
Compression pressure test .................................. DI01-15
Cylinder pressure leakage test ............................ DI01-17
Tightening torque .................................................. DI01-18
REMOVAL AND INSTALLATION .............................. DI01-21
Engine mounting ................................................... DI01-21
Engine assembly - removal .................................. DI01-22
DISASSEMBLY AND REASSEMBLY ........................ DI01-34
Components and special tools ............................. DI01-34
Inspection before disassembly and reassembly .. DI01-35
Engine accessories .............................................. DI01-36
Engine overhaul .................................................... DI01-50
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-3
Engine Structure
Front View
Rear View
1. TVD (Torsional Vibration Damper)
7. Viscos clutch
13. Oil filter
2. Air conditioner compressor
8. Auto tensioner pulley
14. Vacuum pump
9. Auto tensioner
15. Crank position sensor

4. Idle pulley
10. Poly-grooved belt
16. EGR valve
11. Cam position sensor
6. Alternator
12. Drive plate (M/T: DMF)
18. EGR center pipe
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-4
Top View
24. Fuel pipe
29. Booster pressure sensor
20. Intake manifold
25. Injector
30. PCV valve and oil separator
21. Water outlet port
26. Fuel return line
31. Oil dipstick
22. Common rail
27. Oil filler cap
32. EGR-LH pipe
23. Fuel pressure sensor
28. Glow plug
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-5
Left Side View
Right Side View
42. Turbo charger booster vacuum
33. Cylinder head
38. EGR-RH pipe
34. Cylinder block
39. PCV valve and oil separator
35. Oil pan
40. Oil dipstick
36. Drain plug
41. High pressure pump
44. EGR valve
37. Turbo charger
ENGINE ASSEMBLY
DI ENG SM - 2004.9
modulator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-6
Specifications
Description
Specification
D27DT / 5-cylinder
Engine
Type / Number of cylinders
Cylinder
Inner diameter (mm)
86.2
Stroke (mm)
92.4
Displacement (cc)
2696
Compression ratio
18:1
Maximum output (ps/rpm)
170/4,000
Maximum torque (kg.m/rpm)
34.7/1,800
Idle speed
Valve
For Manual Transmission
750 20 rpm
For Automatic Transmission
750 20 rpm
Intake
Exhaust
Camshaft
Type
Fuel system
Fuel type
Opens (BTDC)
16
Closes (ABDC)
33
Opens (BBDC)
46
Closes (ATDC)
21
DOHC
Low sulfur diesel
Vane pump in HP pump
Fuel pump type

Fuel supply pressure
Water separation in fuel filter

Fuel tank capacity ( )
Lubrication system
HP pump inlet port: max. 400 mbar

HP pump outlet port (with IMV fully open):
over 1,050 bar
at every 10,000 km
80
SAE 10W40, 5W40
Oil specification
(MB Sheet 229.1, 229.3 approved oil)

Forced delivery
Lubrication type
Full flow, filter element type
Oil filter type
6.8 ~ 8.3
Oil capacity ( )
Cooling system
Cooling type
Water cooling type
Cooling fan operation type
Belt operated type
Thermostat: Fully
(Open: 100C)
Opening
temperature (C)
Type
Coolant capacity ( )
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
85
WAX pellet type
11.5
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-7
ENGINE PERFORMANCE CURVE
Torque [Nm]
Output [PS]
Output and Torque
Speed [rpm]
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-8
Boost pressure [bar]
Oil temperature [C]
Oil pressure [bar]
Oil Temperature/Pressure and Boost Pressure
Speed [rpm]
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-9
GENERAL DIAGNOSIS
Condition
Hard Starting
(With normal
cranking)
Replace the fuse.
Faulty spark plug.
Clean, adjust the plug gap or

replace.
Electric leakage at the high

tension cable.
Replace the cable.
Poor connection of the high

tension cable or lead wires.
Replace the cable or wires.
Faulty ignition coil.
Lack of fuel in the fuel tank.
Feed the fuel.
Dirty or clogged fuel filter.
Replace the filter.
Clogged fuel pipe.
Clean the fuel pipe.
Malfunction of the fuel pump.
Replace the fuel pump.
Malfunction of the fuel injector.
Replace the injector.
The foreign material in the fuel

tank.
Clean the fuel tank.
Poor tightening spark plug.

Compression
Cracked cylinder head gasket.
Replace the gasket.
Inadequate the valve clearance.
Adjust the clearance.
Leakage of the valve clearance.
Repair the valve.
Interference of the valve stem.
Replace the valve or the valve

guide.
Low elasticity or damage of the

valve spring.
Replace the valve spring.
Abnormal interference of pistons

and cylinders.
Replace the piston ring.
Excessive wear of pistons, rings,

or cylinders.
Replace the ring or the piston

and boring or replace the
cylinder.
Broken timing belt.
Replace the belt.
Loosening, damage or leakage of

the vacuum hose.

replace it.
Leakage of intake system.
Replace intake system.
Decline of
Compression
Pressure
Malfunction of
Ignition System
Faulty spark plug.
Electric leakage or poor

connection of the high tension
cable.

replace it.
Decline of
Compression
Pressure
Others
ENGINE ASSEMBLY
DI ENG SM - 2004.9
Correction
Faulty fuse.
Malfunction of
Ignition System
Malfunction of
Fuel System
Lack of Engine
Power
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-10
GENERAL DIAGNOSIS (Contd)

Condition
Lack of Engine
Power
Rough Engine
Idling
Clogged fuel pipe.
Clean the pipe.
Clogged or contaminated fuel

filter.
Replace the filter.
Others
Clogged exhaust system.
Check and repair the system.

cleaner element.

element.
Leak of the intake manifold

gasket.
Replace the gasket.
Dragging brakes.
Repair or replace the brakes.
Decline of
Compression
Pressure
Refer to Compression Pressure

Test.

Test.
Malfunction of
Fuel System
Clogged fuel pipe.
Clean the pipe.

filter.
Replace the filter.

regulator.
Replace the regulator.

replace it.
Malfunction of the ignition coil.

cleaner element.

element.

gasket.
Replace the gasket.
Poor connection or damage or

leakage of the vacuum hose.

replace it.
Decline of
Compression
Pressure

Test.

Test.
Malfunction of
Ignition System
Poor spark plug or Poor adjustment of the plug gap.
Replace the plug or adjust the

gap.

replace it.
Malfunction of the air cleaner

system.

system.

gasket.
Replace the gasket.
Others
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Malfunction of
Fuel System
Malfunction of
Ignition System
Engine Hesitate
(Upon pressing
accelerating
pedal, the engine
makes delayed
response This
situation is
remarkable when
cruising or
starting.)
Probable Cause
Others
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-11

Condition
Engine Surging
(Engine power
makes
fluctuation in a
fixed speed and
speed changes
without
operating the
accelerating
pedal.)
Overheat

Test.

Test.
Malfunction of
Fuel System
Clogged fuel pipe.
Clean the pipe.

filter.
Replace the filter.

regulator.
Replace the fuel pressure

regulator.

cable.

replace it.

gasket.
Clean or replace the gasket.
Leakage of the vacuum hose.

replace it.
Overheated
Engine
Malfunction of
Fuel System
Abnormal spark plug.
Replace the spark plug.
Adjust the ignition timing

replace it.
Malfunction of
Ignition System

filter and fuel pipe.
Clean or replace the fuel filter and

the fuel pipe.
Others

gasket.
Replace the gasket.
Excessive carbon deposit due to

abnormal combustion.
Remove the carbon.
Lack of coolant.
Refill coolant.
Replace the thermostat.
Malfunction of the cooling fan.
Check or replace the cooling fan.
Poor water pump performance.
Replace the pump.
Clogged or leaky radiator.
Clean, repair or replace the

radiator.
Poor engine oil.
Replace engine oil with the

specified one.
Blocking oil filter or strainer.
Clean or repair the oil filter or the

strainer.
Lack of engine oil.
Refill oil.
Poor oil pump performance.
Replace or repair the pump.
Leakage of oil
Repair.
Damaged cylinder head gasket.
Replace the gasket.
Malfunction of
Ignition System
Malfunction of
Cooling System
Malfunction of
Lubrication
System
Other
ENGINE ASSEMBLY
DI ENG SM - 2004.9
Correction
Decline of
Compression
Pressure
Others
Excessive
Detonation
(According to
the opening
range of Malfunction of
metallic is made
with abnormal
explosion )
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-12

Condition
Poor Fuel
Consumption
Excessive
Consumption of
Engine Oil
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Correction
Decline of
Compression
Pressure

Test.

Test.
Malfunction of
Fuel System
Leakage of the fuel tank or the

fuel pipe.
Repair or replace the fuel tank or

the fuel pipe
Malfunction of
Ignition System
Abnormal spark plug

(Excessive carbon deposit,
inadequate gap, burnt electrode).
Replace the plug.

cable.
Connect the cable normally or

replace it.
Malfunction of
Cooling System
Repair the thermostat.
Others
Improperly installed valve.
Repair or replace the valve.
Low pressure of tires.
Adjust the pressure of tires.
Loosened oil drain plug.
Tighten the plug.
Loosened oil pan bolt.
Tighten the bolt.
Loosened oil filter.
Tighten the filter.
Loosened oil pressure switch.
Tighten the switch.
Leakage of camshaft front oil seal.
Replace the seal.
Leakage of crankshaft front oil seal.
Replace the seal.
Leakage at the cylinder head

cover gasket.
Replace the gasket.
Damage of the cylinder head

gasket.
Replace the gasket.
Stuck piston ring.
Remove carbon and replace the

ring.
Worn piston or cylinder.
Replace the piston or the

cylinder.
Worn piston ring or ring groove.
Replace the piston or ring.
Inadequate position of the piston

ring cutting part.
Adjust the position.
Abrasion or damage of the valve

system.
Replace the valve system.
Inadequate oil viscosity.
Replace with the specified one.
Loosening of the oil pressure

switch.
Tighten the switch.
Lack of engine oil.
Refill oil.
Blocking oil strainer.
Clean the strainer.
Lowered function of the oil pump.
Replace the pump.
Abrasion or damage of the oil

pump relief valve.
Replace the valve.
Leakage of
Engine Oil
Oil Mixing in Combustion Chamber
Low Oil
Pressure
Probable Cause
Malfunction of Lubrication System
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-13

Condition
Engine Noise
DI ENG SM - 2004.9
Correction
Inadequate valve clearance
Adjust the valve clearance.
Abrasion of valve stem or guide.
Replace the valve stem or the

guide.
Weak valve spring.
Replace the spring.
Piston, Ring,
Cylinder Noise
Abrasion of the piston, the ring or

the cylinder.
Boring the cylinder or replace the

piston, the ring or the cylinder.
Connecting Rod
Noise
Abrasion of the connecting rod

bearing.
Loosened the connecting rod nut.
Tighten to the specified torque
Abrasion of the crankshaft

bearing.
Abrasion of the crankshaft

journal.
Grind or replace the crankshaft

journal.
Loosened bearing cap bolt.
Excessive clearance of the

crankshaft thrust bearing.
Adjust or replace.
Low oil pressure.
Refer to Low Oil Pressure in

this section.
Valve Noise
Crankshaft Noise
ENGINE ASSEMBLY
Probable Cause
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-14

OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may
help you in locating and repairing most leaks.
Finding the Leak

1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid, etc.
Black Light and Dye Method

A dye and light kit is available for finding leaks, Refer to
the manufacturer's directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle normal operating conditions as
directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
2. Identify where the fluid is leaking from.

2.1 After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2.2 Wait a few minutes.
2.3 You should be able to find the approximate
location of the leak by the drippings on the
paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent.
4.1 Clean the area well.
4.2 Dry the area.
4.3 Operate the vehicle for several miles at normal
operating temperature and varying speeds.
Repairing the Leak

Once the origin of the leak has been pinpointed and traced
back to its source, the cause of the leak must be determined in order for it to be repaired properly. If a gasket is
replaced, but the sealing flange is bent, the new gasket
will not repair the leak. The bent flange must be repaired
also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a
leak.
Gaskets
The fasteners are tightened improperly or the threads
are dirty or damaged.
The flanges or the sealing surface is warped.
There are scratches, burrs or other damage to the
sealing surface.
4.4 After operating the vehicle, visually check the

suspected component.
The gasket is damaged or worn.
4.5 If you still cannot locate the leak, try using the
powder or black light and dye method.
An improper seal was used (where applicable).
Powder Method
There is cracking or porosity of the component.
Seals
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder)

to the suspected area.
The seal bore is damaged (scratched, burred or nicked).
3. Operate the vehicle under normal operating

conditoins.
Improper installation is evident.
4. Visually inspect the suspected component. You

should be able to trace the leak path over the white
powder surface to the source.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
The seal is damaged or worn.

There are cracks in the components.
The shaft surface is scratched, nicked or damaged.
A loose or worn bearing is causing excess seal wear.
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-15
COMPRESSION PRESSURE TEST

The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and
exhaust vale, cylinder head gasket). This test provides current engine operating status.
Notice
Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from moving
components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle.
Specifications
Compression ratio
18 : 1
Test temperature
Compression pressure
at normal operating temperature (80C)

Normal value
32 bar
Minimum value
18 bar
Permissible pressure difference between individual cylinders
ENGINE ASSEMBLY
DI ENG SM - 2004.9
Max. 3 bar
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-16
Measuring Procedure
Notice
Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Discharge the combustion residues in the cylinders before testing the compression pressure.
Apply the parking brake before cranking the engine.
1. Warm the engine up to normal operating temperature

(80C).
2. Disconnect the fuel rail pressure sensor connector to
cut off the fuel injection.
3. Place the diagram sheet to compression pressure tester.
4. Remove the glow plugs and install the compression

pressure tester into the plug hole.
Tightening torque (Tester)
15 Nm
5. Crank the engine for approx. 10 seconds by using the

start motor.
6. Record the test result and measure the compression
pressure of other cylinders with same manner.
7. If the measured value is not within the specifications,
perform the cylinder pressure leakage test.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-17
CYLINDER PRESSURE LEAKAGE TEST

If the measured value of the compression pressure test is not
within the specifications, perform the cylinder pressure leakage test.
Permissible Pressure Leakage

Test temperature
at normal operating temperature (80C)
At whole engine
Max. 25 %
At valve and cylinder head gasket
Max. 10 %
At piston ring
Max. 20 %
Notice
Perform the pressure in order: 1 - 2 - 3 - 4 - 5

Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the engine oil into the
combustion chamber)
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-18
TIGHTENING TORQUE
NO.
Size
Quantity
Tightening Torque
Oil nozzle
M6 x 22
10 1
Main bearing cap
M11 x 62
12
Connecting rod cap
M9 x 52
Rear cover
M6 x 20
10 1
Oil pump
M8 x 35SOC
25 2.5
Oil baffle plate assembly
M6 x 20
10
10 1
M6 x 16
10 1
M6 x 40
10 1
M6 x 60
10 1
M6 x 70
10 1
M8 x 80SOC
25 2.5
Flywheel
M10 x 30
Crankshaft hub
M18 x 50
M6 x 20
24
10 1
M6 x 35
10 1
M6 x 38
10 1
M6 x 40
25 2.5
M8 x 40
25 2.5
M14 x 1.5-8-1
65 5
M7 x 16
20 2 x 90 + 10
M8 x 25
M8 x 50
M12 x 177
11
M12 x 158
Step3: 3 x 90 + 10
M8 x 60
24
25 2.5
M8
10
15 1.5
25 2.5
90 10
1
2
3
8
9
10
Name
T.G.C.C
Oil pan
11
High pressure pump assembly
12
High pressure pump sprocket assembly
13
High pressure pump bracket
14
Cylinder head assembly
15
Camshaft cap
16
Stud bolt
17
Camshaft sprocket (Intake)

Camshaft sprocket (Exhaust)
M11 x 52
55 5
90 10
40 5
90 10
45 5
90 10
325 33
90 10
25 2.5
Step1: 20 Nm 2 Nm
Step2: 85 Nm 5 Nm
18
Chain tensioner
M22
65 5
19
M14
22 2.2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI01-19
NO.
20
Name
Auto tensioner
Size
Quantity
Tightening Torque
M8 x 45(LOWER)
32 3
M12 x 90
82 6
21
Water pump assembly
M6 x 50
10 1
22
Water pump pulley
M6 x 12
10 1
23
Hot water inlet pipe assembly
M6 x 12
10 1
24
Alternator bracket
M8 x 32
25 2.5
25
Alternator
M10 x 90
46 4.6
26
Air conditioner compressor assembly
M8 x 95
46 4.6
Air conditioner compressor bracket
M8 x 25
25 2.5
assembly
M8 x 60
25 2.5
Air conditioner compressor sub
M6 x 14
10 1.0
bracket assembly
M8 x 16
25 2.5
M8 x 45
25 2.5
M8 x 130
25 2.5
27
28
29
Intake manifold
30
Bracket
M6 x 16
10 1.0
31
Knock sensor
M8 x 28
20 2.6
32
Camshaft position sensor
M8 x 16
12 1.7
33
M6 x 16
10 1.0
34
Exhauster manifold
M8
10
40 4
35
Turbo charger assembly
M8
25 2.5
36
Turbo charger adaptor piece
32 3.2
37
Nut
M8
25 2.5
38
Combination bolt
M8 x 22
25 2.5
39
T/C oil supply pipe
M6 x 16 (Cylinder block side)
25 2.5
M16 (T/C side)
20 2.0
M6 x 16 (T/C side)
10 1.0
M6 x 16 (Cylinder block side)
10 1.0
M8 x 22
25 2.5
M6 x 16
10 1.0
M8 x 22
35 2.0
M6 x 16
10 1.0
M8 x 16
25 2.5
EGR-RH pipe nut
M8
35 2.0
44
Glow plug cable nut
M5
15 3
45
Vacuum pump
M6 x 20
10 1.0
M6 x 25
10 1.0
M6 x 65
10 1.0
M6 x 85
10 1.0
M6 x 35
21
23 2.3
40
T/C oil return pipe
41
EGR valve assembly
42
EGR-LH pipe bolt
43
46
47
EGR combination bolt
Cooling fan bracket assembly
Cylinder head cover
ENGINE ASSEMBLY
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI01-20
NO.
Name
Size
Quantity
Tightening Torque
M6 x 16SOC
10 1.0
48
Vacuum modulator
49
WDT combination bolt
M6 x 16
10 1.0
50
Oil dipstick tube
M6 x 16
10 1.0
M8 x 35SOC
25 2.5
M8 x 50SOC
25 2.5
M8 x 55SOC
25 2.5
M8 x 35SOC
25 2.5
51
Oil filter assembly
52
Fuel rail assembly
53
Injector clamp washer
M6 x 60
54
Fuel pipe clip (H-C)
M6 x 19
10 1.0
55
Fuel pipe clip (C-I)
M6 x 16
10 1.0
56
Crankshaft position sensor
M5 x 17
0.8 0.4
57
GAP
58
59
Wiring
60
Intake manifold bracket
61
62
63
Power steering pump

Piston protrusion
Clearance between connecting rod
and pin boss
64
End play of crankshaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10 1.0
180 + 20
0.7 ~ 1.5
1
M6 x 16
10 1.0
M8 x 16
25 2.5
M8 x 40
25 2.5
M8 x 100
25 2.5
NUT
25 2.5
0.765 ~ 1.055
0.05 ~ 0.31
NEW: 0.100 ~ 0.245 mm // USED: 0.300 mm
ENGINE ASSEMBLY
DI ENG SM - 2004.9
DI02-1
SECTION
00 DI02
ENGINE HOUSING
Table of Contents
CYLINDER HEAD/CYLINDER BLOCK ....................... DI02-2
Cylinder head .......................................................... DI02-2
Camshaft assembly .............................................. DI02-16
Timing chain assembly .......................................... DI02-24
Cylinder block ....................................................... DI02-28
CRANKSHAFT ........................................................... DI02-31
Arrangement of thrust washers and bearings ...... DI02-32
Torsional vibration damper ................................... DI02-37
Diassembly and reassembly ................................. DI02-38
FLYWHEEL ................................................................ DI02-41
Dual mass flywheel (DMF, Manual transmission
equipped vehicle) ................................................. DI02-41
PISTON AND CONNECTING ROD ............................ DI02-43
Piston ring ............................................................. DI02-44
Cylinder inner diameter and piston size ............... DI02-45
Disassembly and reassembly ............................... DI02-46
HIGH PRESSURE PUMP (HPP) ............................... DI02-50
Components locator ............................................. DI02-50
Disassembly and reassembly ............................... DI02-51
VACUUM PUMP ........................................................ DI02-56
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-2
CYLINDER HEAD/CYLINDER BLOCK

CYLINDER HEAD
Cylinder head bolt
Oil return check valve
System Characteristics
4-valve DOHC valve mechanism
Intake port
Swirl and tangential port

4-bolt type cylinder head bolt
Water jacket integrated casting
Integrated chain housing and cylinder head
Exhaust port
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Oil gallery: drilled and sealing with cap and screw plug
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-3
Cylinder Head Pressure Leakage Test

Preceding Works:
- Removal of cylinders
- Removal of intake and exhaust manifold
- Removal of valves
Test Procedures
1. Place the pressure plate on a flat-bed work bench.
2. Install the cylinder head on the pressure plate.

Tightening torque
60 Nm
3. Immerse the cylinder head with the pressure plate into

warm water (approx. 60C) and pressurize with
compressed air to 2 bar.
Notice
Examine the cylinder head for air bubbling. If the air

bubbles are seen, replace the cylinder head.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-4
Cylinder Head Mating Surface Check

Specifications
Height A (cylinder head parting surface - cylinder head cover parting surface)
Minimum height after machining
Flatness
142.4 mm
in longitudinal direction
0.08 mm
in transverse direction
0.0 mm
Permissible variation of parallelism of top parting surface to bottom in longitudinal direction

Peak-to-valley height
Valve recess a
142.9 ~ 143.1 mm
within 0.1 mm
0.004 mm
Intake valve
0.1 ~ 0.7 mm
Exhaust valve
0.1 ~ 0.7 mm
Measurement
1. Measure the cylinder head height A.
Limit
Over 142.4 mm
Notice
If the height is less than the limit, the cylinder head

must be replaced.
2. Insert the valves into the valve guides and measure the
recesses.
Valve recess a
0.1 ~ 0.7 mm
Notice
If the measured value is out of the specified range,

machine the valve seat as much as necessary until
the specified value is achieved.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-5
Cylinder Head
- Disassembly and Reassembly
Disassembly
Preceding Works:
- Removal of fan belt
- Removal of fuel supply and return lines
- Removal of EGR related pipes and oil dipstick tube
- Removal of intake manifold mounting bracket
- Removal of injector fuel line and connector, and glow plug
connector
Notice
Plug the openings of injector holes and common
rail with the protective caps.
1. Remove the cylinder head cover.
2. Remove the camshaft position sensor.

Installation Notice
The intake manifold can be interfered by the sensor
when installing.
3. Mark on the intake camshaft sprocket and exhaust

camshaft sprocket for timing setting during installation.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-6
5. Hold the camshafts and remove the intake camshaft

sprocket and exhaust camshaft sprocket.
6. Pull out the lock pins with a sliding hammer and remove
the upper guide rail.
Notice
Correctly align the electronic control module onto

the shift plate by using two central pins when
installing.
7. Remove the oil cooler, then remove the intake manifold.

Installation Notice
The intake manifold can be interfered by the
cylinder head bolt (M8 x 50).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-7
8. Remove the cylinder head bolts according to the
numerical sequence.
M8 x 25
M8 x 50
M12 x 177
M12 x 158
:
:
:
:
2 EA
2 EA
11 EA
1 EA
(Vacuum pump side)
9. Measure the length of cylinder head bolts.

Installation Notice
If the maximum length is exceeded by 2 mm,
replace the cylinder head bolt.
Length when new
Maximum Limit
177 mm
179 mm
158 mm
160 mm
10. Remove the cylinder head.

Notice
Inspect the cylinder head surface.
Store the removed injectors and glow plugs so that
they will not be damaged.
11. Measure the piston protrusion from the mating surface.

Standard
ENGINE HOUSING
DI ENG SM - 2004.9
0.765 ~ 1.055 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-8
Reassembly
1. Install the cylinder head with the steel gasket.
Notice
Make sure to place the TOP mark upward.
2. Tighten the cylinder head bolts to specified torque and

torque angle.
Installation Notice
Step 1 20 2.0 Nm
Tightening torque
Step 2 85 5.0 Nm
Step 3 270 (90 x 3) + 10
Apply the oil on the bolt thread when installing.

Always insert new washer first.
The bolts (12) at vacuum pump side are shorter than
others.
3. Install the HLA device and finger follower. Check the HLA
device with the diagnosis procedures before installation.
Notice
Put the cylinder head on the locating pins.
4. Tighten the camshaft bearing cap bolts.

Intake: #2, #4, #5
Exhaust: #8, #10, #11
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-9
Exhaust: #1, #3, #6
Intake
Intake: #7, #9, #12

Installation Notice
Tightening torque
25 Nm
Check the finger follower positions and align if

needed.
Exhaust
5. Install the intake and exhaust camshaft sprockets and

the timing chain.
Installation Notice
Tightening torque
25 Nm + 90
If the sprocket bolt is stretched over 0.9 mm, replace

it with new one.
Always install the intake camshaft sprocket first.
Ensure that the markings on camshaft sprocket and
timing chain are aligned.
Make sure that the timing chain is securely seated
on the guide rail.
6. Rotate the crankshaft pulley two revolutions and ensure
that the OT mark on the crankshaft pulley and the OT
mark on the camshaft pulley are aligned.
Notice
If the markings are not aligned, reinstall the cylinder

head.
7. Place the bearing cap with the OT marks on both

camshafts facing upward.
Notice
Apply the sealant on the cap (#12) for the vacuum
pump when installing.
Apply the oil on the bearing journals before
installation.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-10
8. Fit the timing chain onto the camshaft sprockets and
install the upper guide rail.
Install the clamping guide rail pin.
Notice
Install the guide rail with slanted side facing
forward.
Be careful not to change the timing of HP pump
when fitting the timing chain.
9. Tighten the intake and exhaust camshaft sprocket bolts.

Installation Notice
Tightening torque
25 2.5 Nm,
90 + 10
10. Install the camshaft position sensor.

11. Apply the Loctite to the bolt and tighten it.
Installation Notice
Tightening torque
10 Nm
12. Check the intake camshaft before installing the vacuum

pump.
13. Install the intake manifold. Install the oil cooler with new
gasket.
Installation Notice
Tightening torque
25 Nm
Ensure that there is no leaks around the coolant

line for #1 cylinder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-11
Installation Notice
Tightening torque
65 5 Nm
15. Install the cylinder head cover assembly.

16. Install the rubber gasket.
17. Tighten the cylinder head cover bolts.

Installation Notice
Tightening torque
10 1.0 Nm
Apply the sealant to the bolts for the vacuum pump

and the timing chain cover.
18. Check the mating surface of the #12 bearing cap and the
cylinder head for contacting.
19. Check if the O-ring is installed in the vacuum pump.
20. Install the vacuum pump with the key groove aligned.
21. Tighten the vacuum pump mounting bolts.
Installation Notice
Tightening torque
ENGINE HOUSING
DI ENG SM - 2004.9
10 1.0 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-12
22. Install the PCV valve assembly on the cylinder head.
Installation Notice
Tightening torque
10 1.0 Nm
23. Engage the engine oil hose and the PCV valve hose.
24. Remove the protective caps and install the new fuel supply
pipes.
Notice
To keep the cleanness and protect the components,
the fuel pipes should be replaced with new ones.
Be careful not to be mixed the fuel pipes because
the pipe appearance of #1 and #3 cylinders and #2
and #4 are same each other.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-13
Intake/Exhaust - Removal/Installation
1. Remove the cylinder head assembly.
2. Install the removed cylinder head on the assembly board

(special tool) and set the supporting bar and lever (special
tool) on the cylinder head.
3. Push the valve spring seat down with the lever and remove
the valve cotter, valve seat and valve spring.
4. Remove the valves from the cylinder head.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-14
Special Tools and Equipment

Application
Compression pressure measuring adapter and gauge

Y99220092B
Pressure plate
(cylinder head pressure leakage
test)
Pressure plate
(intake camshaft pressure leakage
test
Pressure plate
(exhaust camshaft pressure leakage test)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-15
Application
Cylinder head hanger
Supporting bar and lever

Y99220082B
Guide pin extractor

Y99220162B
Intake manifold guide pin

Y99220112B
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-16
CAMSHAFT ASSEMBLY
Finger follower and HLA
Intake camshaft and

exhaust camshaft
Camshaft sprockets
Cylinder head
Camshaft position sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Chain tensioner
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-17
Camshaft Position Sensor

Gap
Hall voltage
<Location of camshaft position sensor>
<Operation principle of hall sensor>
The camshaft position sensor uses hall-effect to set the camshaft position and metallic-magnetic-material sensor end is
attached on the camshaft and then rotates with it. If sensor protrusion passes camshaft position sensors semi-conductor wafer, magnetic field changes direction of electron on the semi-conductor wafer to the current flow direction that
passes through wafer from the right angle. When operation power is supplied from camshaft position sensor, camshaft
hall sensor generates signal voltage. The signal voltage will be 0V if protrusion and camshaft position sensor are near
and 5 V if apart.
ECU can recognize that the No. 1 cylinder is under compression stroke by using this voltage signal (hall voltage).
The rotating speed of camshaft is half of the crankshaft and controls engines intake and exhaust valves. By installing
sensor on the camshaft, can recognize specific cylinders status, compression stroke or exhaust stroke, by using
camshaft position when the piston is moving toward TDC (OT). Especially when started first, it is difficult to calculate the
stroke of a specific cylinder with only crankshaft position sensor.
Accordingly, camshaft position sensor is necessary to identify the cylinders correctly during initial starting. However,
when engine is started, ECU learns every cylinder of the engine with crankshaft position sensor signals so can run the
engine even though the camshaft position sensor is defective during engine running.
Pulse generation
Cam angle 6
Sensor air gap
0.2 ~ 1.8 mm
Tightening torque
10 ~ 14 Nm
Operating temperature
- 40 ~ 130C
Ground
Camshaft sensor
<Circuit diagram of camshaft position sensor>

ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-18
Removal
Preceding Works:
- Removal of fan belt
- Removal of fuel supply and return lines
- Removal of intake manifold mounting bracket
- Removal of EGR pipe and oil dipstick tube
1. Remove the injector fuel line and connector, and glow

plug connector
Notice
Plug the openings of injector holes and common rail

with the protective caps.
2. Remove the cylinder head cover.
3. Remove the camshaft position sensor.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-19
4. Mark on the intake camshaft sprocket and exhaust
camshaft sprocket for timing setting during installation.
6. Hold the camshafts and remove the intake camshaft

sprocket and exhaust camshaft sprocket.
7. Remove the camshaft bearing cap bolts so that the

tightening force can be relieved evenly.
Intake
Intake: #1, #3, #6

Exhaust: #7, #9, #12
* However, there is no specific removal sequence.
Exhaust
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-20
Intake: #2, #4, #5
Exhaust: #8, #10, #11
* Do not remove the bolts at a time completely. Remove
them step by step evenly.
8. Remove the intake and exhaust camshafts from the
cylinder head.
9. Remove the finger follower and the HLA device.

Notice
Avoid contact with hot metal parts when removing

the HLA device immediately after stopping the
engine.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-21
Installation
1. Install the HLA device and finger follower. Check the HLA
device with the diagnosis procedures before installation.
Notice
Put the cylinder head on the locating pins.
2. Place the bearing cap with the OT marks on both

camshafts facing upward.
Notice
Apply the sealant on the cap (#12) for the vacuum

pump when installing.
Apply the oil on the bearing journals before
installation.
3. Tighten the camshaft bearing cap bolts.

Intake: #2, #4, #5
Exhaust: #8, #10, #11
1
10
11
12
Intake: #1, #3, #6

Intake
Exhaust: #7, #9, #12

Installation Notice
Tightening torque
10
25 Nm
Check the finger follower positions and align if

needed.
11
Exhaust
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
DI02-22
4. Install the intake and exhaust camshaft sprockets and
the timing chain.
Installation Notice
Tightening torque
25 Nm + 90 + 10
If the sprocket bolt is stretched over 0.9 mm, replace

it with new one.
Always install the intake camshaft sprocket first.
Ensure that the markings on camshaft sprocket and
timing chain are aligned.
Make sure that the timing chain is securely seated
on the guide rail.
5. Rotate the crankshaft pulley two revolutions and ensure
that the OT mark on the crankshaft pulley and the OT
mark on the camshaft pulley are aligned.
Notice
If the markings are not aligned, reinstall the cylinder

head.

Installation Notice
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
80 8.0 Nm
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-23

Application
HLA remover
Y99220152B
Stem seal installer

Y99220142B
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-24
TIMING CHAIN ASSEMBLY

Chain Drive System
System Layout
Oil injecting direction
7. Oil pump tensioner
2. Upper guide rail
3. Intake camshaft sprocket
9. Crankshaft sprocket
4. Clamping guide rail
10. Oil nozzle
5. HP pump sprocket
11. Tensioner guide rail
6. Lower guide rail
12. Chain tensioner
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-25
Chain
Chain type: Double Bush
Pitch: 9.525 mm
Load limits: 19,000 N
No. of links: 144 EA
Overall length: 1371.6 mm
Replace when the chain is extended by 0.5 % from overall length (Replace if extended by over 6.858 mm)
Chain tensioner
Check valve
* Check valve opening pressure: 0.2 ~ 0.5 bar
The major function of tensioner is optimizing the movement of chain drive system by using spring constant and oil
pressure in the tensioner.
The tensioner performs function of adjusting chain tension to be always tight, not loose, while engine running. By doing
so, can reduce wears of each guide rail and sprocket.
Tightening torque
65 5.0 Nm
(Installed on the cylinder head)
Guide rail
Guide rail is used to optimize the movement of chain drive system like tensioner.
Guide rail can prevent chain slap when chain is extended and reduce chain wears.
Guide rail is needed especially when the distance between the sprockets are too long.
The material is plastic.
Location of guide rail
- Tensioner guide rail: Between crankshaft sprocket and exhaust camshaft sprocket
- Upper guide rail: Between exhaust camshaft sprocket and intake camshaft sprocket
- Clamping guide rail: Between intake camshaft sprocket and HP pump sprocket
- Lower guide rail: Between HP pump sprocket and crankshaft sprocket
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-26
Timing setting
Sprocket marking: 4 points

(Gold marking)
<Timing marking points on chain>
Check marking links on the chain (Gold marking)

Locate a point with two continuous marking links and align it to a marking on crankshaft sprocket ( )
Align respective marking link to each camshaft sprocket (intake and exhaust) marking ( )
Align another marking link to HP pump sprocket marking (
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-27
Removal and Installation

1. Remove the cylinder head assembly.
2. Remove the oil pan.
3. Remove the chain guide rail with a sliding hammer.
4. Remove the chain cover.
5. Remove the oil pump drive chain.

6. Remove the upper guide rail while pushing the retaining
spring with a screwdriver.
7. Remove the lower guide rail.
8. Remove the oil pump drive chain.
9. Remove the tensioner guide rail.
10. Remove the timing chain.

Notice
Thoroughly clean the removed components before

installing.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-28
CYLINDER BLOCK
Deep head bolt thread to prevent the

deformation at cylinder bore surfaces
Internal and external ribs considered
Water jacket design to increase
vibration and strength
the cooling efficiency
Cambering type skirt to reduce the noise
Rib design by considering strength against engine
vibrations and weight
Cambering type skirt design on case housing wall to
reduce the engine noise
Water jacket design to increase the cooling efficiency
of cylinder bore bridge
Deep head bolt thread to prevent the deformation at
cylinder bore surfaces
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Reinforcement of strength
- Main bearing housing / Main bearing cap
- Extended main bearing cap bolt
Reducing the noise, vibration and harshness (NVH)
- Minimize the vibration by adding external ribs
- Adding the ribs around oil pan mating surface
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-29
Knock Sensor
Two knock sensors are located on the cylinder block (intake manifold side).
To detect engine vibration under abnormal combustion, knock sensor has piezoelectric element fixed on the
vibration plate and this vibration plate is fixed on the base. If happens knocking, pistons or connecting rods
vibrate and occurs heavy sounds that hit metal. Knock sensor is used to detect those knockings caused by
abnormal combustions. It controls idling stabilities and turns on the engine warning light when detects injector
damages. And also controls pilot injection very precisely during MAP learning.
When knock sensor is defective, engine ECU corrects injection timing based on MAP values like engine speed,
intake air volume and coolant temperature.
Before checking the knock sensor unit, be sure to check the tightening torque of the sensor and connector
connecting conditions.
Insulating resistance
Min. 1M
Resonance frequency
25 kHz
- 40 ~ 150C
26 8 mV/g (at 5 kHz)
Output voltage
22 ~ 37 mV/g (3 ~ 10 kHz)
22 ~ 57 mV/g (10 ~ 20 kHz)
Tightening torque
20 5 Nm
<Location of knock sensor>

1. Sensor housing
6. Upper contact plate
2. Nut
7. Piezo element
3. Disc spring
8. Lower contact plate
4. Weight
9. Body
5. Insulation disc
ENGINE HOUSING
DI ENG SM - 2004.9
10. Terminal
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-30
Notice
The knock sensor should be tightened with the specified tightening torque. Otherwise, the engine output may
be decreased and the ENGINE CHECK warning lamp may come on. The internal resistance of the sensor is
approx. 4.7 k.
Ground
Knock sensor
Signal
Signal
Knock sensor
Ground
<Circuit diagram of knock sensor>
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-31
CRANKSHAFT
Preceding Works: Removal of end cover
Removal of pistons
Removal of crankshaft sprocket
3. Crankshaft main bearing shells, upper
8. Crankshaft main bearing cap
5. Crankshaft
6. Crankshaft main bearing shells, lower
ENGINE HOUSING
DI ENG SM - 2004.9
9. Crankshaft thrust bearing cap

10. 12-sided stretch bolt ....... 55 5.0 Nm, 90 + 10
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-32
ARRANGEMENT OF THRUST WASHERS AND BEARINGS
1. Crankshaft
4. Crankshaft main bearing shells, lower
2. Crankshaft main bearing shells, upper
Notice
The clearance between bearing shell and bore and between

bearing shell and journal are various. Refer to the table
on next page to select bearings when installing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-33
Dimensions of Crankshaft Main Bearing

(mm)
Color
Crankshaft Journal
Upper Main Bearing
Lower Main Bearing
Blue
57.965 ~ 57.960
2.260 ~ 2.255
2.260 ~ 2.255
Yellow
57.960 ~ 57.955
2.265 ~ 2.260
2.265 ~ 2.260
Red
57.955 ~ 57.950
2.270 ~ 2.265
2.270 ~ 2.265
White
57.950 ~ 57.945
2.275 ~ 2.270
Violet
57.945 ~ 57.940
2.280 ~ 2.275
Crankshaft Bearing
Thrust Bearing
When new
0.027 ~ 0.051
0.026 ~ 0.068
Wear limit
Max. 0.070
Max. 0.080
When new
0.100 ~ 0.254
Wear limit
Max. 0.300
Bearing Clearance
(mm)
Description
Radial clearance
Axial clearance
Matching the Fit Bearing Journal Width to Thrust Washers

(mm)
Fit bearing Journal Width
Thrust Washer Thickness
24.500 ~ 24.533
2.15
24.600 ~ 24.633
2.20
24.70 ~ 24.733
2.25
24.900 ~ 24.933
2.35
25.000 ~ 25.033
2.40
Notice
Measure the crankshaft axial clearance and correct if necessary with appropriate thrust washers.
Thrust washers of the same thickness must be installed on both sides of the fit bearing.
Matching the Crankshaft Bearing Shells to Basic Bearing Bore in Crankcase

Marking of Basic Bearing Bore in Lower Mating Surface
Relevant Crankshaft Bearing Shell With Color Coding
1 punch mark or blue
blue or white - blue
2 punch marks or yellow
yellow or white - yellow
3 punch marks or red
red or white - red
Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft

Marking of Bearing journals on Crank Webs
Relevant Crankshaft Bearing Shell With Color Coding
yellow or white - blue
yellow or white - yellow
red or white - blue
red or white - red
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-34
Selection of Upper Main Bearing Shell

Punch Mark
Color
Blue
Yellow
Red
Selection of Lower Main Bearing Shell
CHANGED BY
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AFFECTED VIN
Mark
Color
Blue
Yellow
Red
White
Violet
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-35
Permanent
magnet
Iron
coil
Standard
position
Ring gear
<Location of crankshaft position sensor>
<Structure of crankshaft position sensor>
The crankshaft position sensor is located near to flywheel on the rear of cylinder block. It generates AC voltage between
increment type driven plate that fixed on flywheel inside. The sensor consists of soft iron core that winded copper wire
on permanent magnet and generates sign wave AC voltage when magnetism on the sensor wheel passes the sensor.
When the crankshaft rotates, + signal will be generated from near the front edge and - signal will be generated from
near the rear edge among teeth on the driven plate near to crankshaft position. The AC voltage increases as the engine
speed increases, however, no signal occurs from the 2-missing-tooth on the increment type driven plate. By using these
teeth, ECU recognizes TDC of No. 1 and 5 cylinders.
ECU converts the alternative signals into digital signals to recognize crankshaft position, piston position and engine
speed. The piston position that coupled with crankshaft is main factor in calculating injection timing. By analyzing the
reference position and camshaft position sensor, can recognize No. 1 cylinder and calculate the crankshaft speed.
<Drive plate>
A. Distance between + max. voltage and - max.

voltage
a. Front edge
b. Rear edge
c. 2-missing-tooth
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI02-36
Ground
Signal
Crankshaft position
sensor
Drive plate
<Circuit diagram of crankshaft position sensor>
Min. voltage: 1.0 V (40 rpm, air gap: 1.3 mm)
Output voltage
( 1 ~ 150 V)
Max voltage: 150 V (7000 rpm, air gap: 0.3 mm)
Sensor unit coil resistance ()
1,090 15 %
Sensor air gap
0.3 ~ 1.5 mm
- 40 ~ 150C
Tightening torque
6 ~ 8 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-37
TORSIONAL VIBRATION DAMPER
Laser welding
Bearing
Pin
Cover
Hub
Bushing
Inertia ring
Pin
Silicone oil
System Description
Components: Hub, inertia ring, cover, bearing, bushing, silicone oil
Functions: The crankshaft pulley optimizes the drive system by reducing the amount of torsional vibration in crankshaft.
Conventional rubber damper is limited in changing materials (rubbers) to absorb vibration, but this crankshaft
pulley (viscous damper), using silicone oil, takes advantage of less changing viscosity according to the
temperature.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-38
DIASSEMBLY AND REASSEMBLY

1. Unscrew the bolts and remove the connecting rod journal
bearing and bearing caps.
Notice
Position the #1 piston at TDC and remove the piston

connecting rod journal bearing caps.
2. Remove the bearing cap bolts.

3. Remove the bearing caps.
Notice
The crankshaft bearing caps are marked with
stamped numbers. Start to remove from the
crankshaft pulley side.
Do not mix up the bearing shells.
4. Remove the bearing caps and lower thrust bearing.
5. Separate the lower bearing shells from the bearing caps.
6. Remove the crankshaft.
7. Remove the upper thrust washers.

8. Remove the upper bearing shells from the crankcase.
Notice
Do not mix up the bearing shells.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-39
Crankshaft - Reassembly
1. Thoroughly clean the oil galleries and check the journal
section and bearings. Replace if necessary.
2. Coat the upper thrust washers with oil and insert into the
crankcase so that the oil grooves are facing the crank
webs (arrow).
3. Coat the lower thrust washers with oil and insert into the
crankcase so that the oil grooves are facing the crank
webs (arrow).
Notice
The retaining lugs should be positioned in the grooves

(arrow).
Notice
If the maximum permissible length of L= 63.8 mm is

exceeded, the 12-sided stretch bolts should be
replaced.
4. Coat the new crankshaft with engine oil and place it on

the crankcase.
5. Install the crankshaft bearing caps according to the
markings and tighten the bolts.
Installation Notice
Tightening torque
55 5 Nm + 90 + 10
Install from #1 cap.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-40
6. Position the #1 piston at TDC and install the crankshaft.
7. Install the piston connecting rod journal to the crankshaft
journal and tighten the bolts.
8. Measure the crankshaft bearing axial clearance.
When new: 0.100 ~ 0.245 mm
When used: 0.300 mm
9. Rotate the crankshaft by hand and check whether it
rotates smoothly.
CHANGED BY
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AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-41
FLYWHEEL
DUAL MASS FLYWHEEL (DMF, MANUAL TRANSMISSION EQUIPPED VEHICLE)
Primary wheel
Ring gear
Primary wheel
Secondary
wheel
Plastic bushing
System Description
This flywheel is installed to the rear end of crankshaft and transfers the output from the engine to the power train
mechanism. When starting the engine, this drive the crank train mechanism initially by using the power from the start
motor. Also, DMF measure the crankshaft speed, sends the signals to ECU, and controls the ignition timing.
Conventional flywheel
ENGINE HOUSING
DI ENG SM - 2004.9
DMF
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AFFECTED VIN
DI02-42
Structure
Function and characteristics
When the output changes from the engine is high during
power stroke ( ): The damper absorbs the shocks to
reduce the changes to transmission.
When the output changes from the engine is low during
compression stroke ( ): The damper increases the torque
changes to clutch.
<Example of DMF operation>
Angular acceleration amplitude [1/s 2]
<Torque change curve of engine and drive shaft>
Conventional system
DMFW
Engine
Engine
Transmission
Transmission
Speed [rpm]
Speed [rpm]
Function
Filters irregularities of engine: The secondary flywheel
operates almost evenly so does not cause gear noises
The mass of the primary flywheel is less than
conventional flywheel so the engine irregularity
increases more (less pulsation absorbing effect)
Transmission protection function: Reduces the load to
powertrain (transmission) by blocking the irregularity
of engine
Characteristics of DMF
Reduced vibration noise from the powertrain by blocking
the torsional vibrations
Advantages of DMF
Improved torque response by using 3-stage type spring:
Strengthens the torque response in all ranges (low,
medium, and high speed) by applying respective spring
constant at each range.
Stable revolution of the primary and secondary wheel
by using planetary gear: Works as auxiliary damper
against spring changes
Less heat generation due to no direct friction against
spring surface: Plastic material is covered on the spring
outer surface
Increased durability by using plastic bushing (extends
the lifetime of grease)
Enhanced vehicle silence and riding comforts: reduced

engine torque changes
Reduced shifting shocks
Smooth acceleration and deceleration
CHANGED BY
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AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-43
PISTON AND CONNECTING ROD
1. No.1 compression ring
3. Oil ring
Description
Cylinder bore diameter
Piston outer diameter (D1)
Clearance between bore and piston
Piston cooling gallery
Pin offset
Compression ratio
Length of piston pin
Material of top ring / coating
Tightening torque of connecting rod bolt
Permissible weight difference of connecting rod
D27 DT ENG
86.2 (0~0.018) mm
86.133
(0.009)
mm
74
Applied
0.15 mm (Thrust)
18 : 1
71.2 mm
Steel / Gas nitride
40 5.0 Nm, 90 + 10
4g
Thickness of connecting rod bearing (Red)
1.806 ~ 1.809 mm
Thickness of connecting rod bearing (Yellow)
1.809 ~ 1.812 mm
Thickness of connecting rod bearing (Blue)
1.812 ~ 1.815 mm
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-44
PISTON RING
3. Oil ring
5. Coil spring and oil control ring
6. Hook spring
Replacement of Piston Ring

Measure piston ring end play.
- Piston ring end play (mm)
1st groove: 0.20 ~ 0.35
2nd groove: 0.20 ~ 0.35
3rd groove: 0.20 ~ 0.40
- Clearance between piston ring and piston (mm)
1st compression ring: 0.075 ~ 0.119
2nd compression ring: 0.050 ~ 0.090
3rd oil ring: 0.030 ~ 0.070
Install the piston so that Y marking on piston head is
facing in the direction of travel. Arrange the piston ring
ends to be 120 apart.
Adjust the hook spring joint in the oil ring 180 away from
the ring end.
CHANGED BY
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AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-45
CYLINDER INNER DIAMETER AND PISTON SIZE
(Unit : mm)
Engine
Code
Used piston
Cylinder Diameter
Piston Diameter
D27DT
A or X
86.200 ~ 86.206
86.124 ~ 86.130
A, B or X
86.206 ~ 86.212
86.129 ~ 86.137
B or X
86.212 ~ 86.218
86.136 ~ 86.142
+5
+5
86.250 ~ 86.260
86.167 ~ 86.181
+ 10
+ 10
86.300 ~ 86.310
86.217 ~ 86.231
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI02-46
DISASSEMBLY AND REASSEMBLY

1. Install the compression ring and oil ring on the piston
with a special tool.
Arrange the piston ring ends to be 120 apart.

Notice
Install the No.1 and No.2 pistons so that Y marking

on piston head is facing upward.
No.1 piston ring is thicker than No.2 piston ring.
Arrange the oil ring end to opposite position of
current ring end.
Oil ring is not directional.
Make sure that the piston ring end is not aligned to
axial direction and lateral direction.
2. Check the clearance of piston oil ring and compression
ring with a thickness gauge and adjust if necessary.
1st groove
0.20 ~ 0.35 mm
2nd groove
0.20 ~ 0.35 mm
3rd groove
0.20 ~ 0.40 mm
* Piston ring end play (mm)

1st groove: 11.0 mm
2nd groove: 10.5 mm
3rd groove: 7.0 mm
3. Check the clearance of piston rings with a thickness
gauge and adjust if necessary.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
No.1 compression ring
0.075 ~ 0.119 mm
2nd compression ring
0.050 ~ 0.090 mm
3rd oil ring
0.040 ~ 0.080 mm
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-47
4. Fit the piston onto connecting rod so that the marking
on piston crown and locking slot are facing to straight
ahead direction.
Notice
Install the piston so that the piston recess (marking)

or the stamped surface of connecting rod is facing to
straight ahead direction.
5. Lubricate piston pin and push in by hand.

Notice
Do not heat up the piston.

6. Place new snap rings into the grooves.
Notice
The snap rings should be replaced with new one.

7. Lubricate the cylinder bore, connecting rod bearing
journals, connecting rod bearing shells and pistons.
8. Push piston into the cylinder with a wooden stick.
Notice
The marking on the piston crown must be facing to

straight ahead direction.
9. Insert connecting rod bearing shells.

Notice
The upper and lower connecting rod bearings have
same appearance. Therefore, make sure to check
the part number before replacing them.
Install bearing rod bearing cap so that so that the
retaining lugs are on the same side of the
connecting rod bearing.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-48
10. Measure stretch shaft diameter of the connecting rod
bolts.
Limit C
7.1 mm
11. Lubricate the new connecting rod bolts and tighten.

Installation Notice
Tightening torque
40 5.0 Nm,
90 + 10
End play of connecting rod cap

Specified value
0.5 ~ 1.5 mm
12. Position piston to TDC and measure the distance between

piston and mating surface of crankcase.
Permissible piston
protrusion
0.765 ~ 1.055 mm
Measure at both ends of axial direction.
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AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-49

Application
Piston protrusion measuring jig

Y99220122B
Piston insertion jig

Y99220172B
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI02-50
HIGH PRESSURE PUMP (HPP)

COMPONENTS LOCATOR
High pressure
line
Low pressure line
Venturi return line
IMV connector
Inlet Metering
Valve (IMV)
High pressure
supply line
1. Inlet Metering Valve (IMV)
7. Low pressure pump
2. Hydraulic pressure head
8. Fuel temperature sensor
3. Plunger
9. Venting
4. Drive shaft and cam ring
10. High fuel pressure supply line
5. Housing
11. Pressure regulator
6. Roller and shoe
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-51

Preceding works:
- Removal of fan belt (including cooling fan and fan clutch)
and fan shroud
- Removal of intake manifold assembly
- Removal of water pump pulley
- Removal of auto tensioner
- Removal of EGR pipe
- Removal of oil dipstic gauge
Notice
To prevent oil leaks, store the removed auto tensioner it

upright position.
Be careful not to damage the rubber bellows.
Plug the oil ports for HP pump with sealing caps.
1. Set crankshaft pulley to OT point. Open the oil filler cap

and check if the cam shaft notch marking is aligned to
OT point.
2. Remove the cooling fan idle pulley with a pulley holder

(special tool).
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI02-52
3. Remove the cooling fan bracket assembly.
Notice
Be careful not to get the sealant or foreign materials

into the engine.
4. Place the marks on the chain and HP pump sprocket for

installation.
5. Remove the vacuum modulator bracket.

6. Remvoe the fuel pipes and wiring connectors which
connected to fuel pump.
7. Turn the crankshaft pulley to the counter clockwise

direction to ATDC 45 then remove the chain tensioner.
Installation Notice
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
64 5 Nm
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-53
8. While insert finger and push the chain guide backward
direction and turn the crankshaft pulley to ATDC 65 by
counter clockwise direction until feel the chain guide
inclined backward.
9. Install a special tool into the cooling fan bracket hole to

hold the sprocket.
10. Remove the sprocket bolts and center nut and after
slightly lifted up the chain, remove the pump sprocket.
Installation Notice
Tightening torque
Nm
Sprocket bolt
20 Nm + 90
Center nut
65 5 Nm
11. Remove the HP pump bearing with HP pump bearing

puller (special tool).
Notice
Do not apply excessive force. The timing chain may

deviates.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-54
12. Remove the HP pump mounting bracket.
Installation Notice
Tightening torque
24 2.4 Nm
13. Unscrew the external bolts and remove the HP pump

while rocking and tapping it with a rubber hammer.
Notice
To prevent HP pump shaft damaging, do not apply

excessive impact.
Do not apply excessive force. The timing chain may
deviates.
14. Remove the HP pump.

15. Install the new HP pump with sealing caps.
Notice
Remove the sealing caps only when connecting the

pipes and hoses.
16. When replaced the HP pump, initialize the fuel pressure
by using SCAN-100. Refer to Trouble Diagnosis section
in this manual.
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AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-55
Notice
If the initialization of fuel pressure has not been

performed, the engine ECU controls new HP pump
with the stored offset value. This may cause the poor
engine output.
Install in the reverse order of removal and tighten the

fasteners with the specified tightening torque.
1. HP pump sprocket
2. 12-sided sprocket mounting bolt
3. HP pump bearing housing
4. HP pump (High Pressure Pump)
5. HP pump shaft
6. HP pump center nut
7. HP pump outer bolt
8. HP pump bearing shaft
9. Oil gallery
10. Bearing bushing
11. Gasket
* Tightening torque
Center nut
(M14 x 1.5 - 1EA)
Outer bolt
(M8 x 55 - 3EA)
Sprocket bolt
(M7 x 13 - 3EA)
ENGINE HOUSING
DI ENG SM - 2004.9
65 5.0 Nm
24 2.4 Nm
20 Nm 90
CHANGED BY
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AFFECTED VIN
DI02-56
VACUUM PUMP
Caution
1. Removing the engine mounting insulator

To secure the enough working space for removal of the vacuum pump in the DI engine equipped vehicle, remove
the engine mounting insulator bracket before starting the operation. The distance between panels in engine
compartment is 27mm.
Working space before removing

the vacuum pump(27mm)
Working space after removing

the vacuum pump (41mm)
2. Tightening torque (10 1.0 Nm)

The vacuum pump is installed with three bolts. And, there is no tightening point at upper area of the vacuum
pump. Therfore, the oil leak may be occurred during the engine running if the mounting bolts are not properly
tightened. The bolts should be tightened with a torque wrench and special tool (A9917 023 0B) to get the correct
tightening torque.
Special tool (Adaptor socket

for removal of vacuum pump)
A9917 023 0B
CHANGED BY
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AFFECTED VIN
Within 190mmm
(torque: 4 ~ 12 Nm)
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-57

Preceding works:
- Disconnection of negative battery cable
- Removal of engine acoustic cover
This section also describes the removal and installation procedures for the engine mounting insulator bracket.
1. Unscrew the lower bolt (10mm) from the cooling fan shroud cover and remove the cover. Doing this eliminate the
interference between the cooling fan and shroud during lowering the engine.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-58
2. Remove the FFH coolant inlet hose bracket nut and the engine ground. Move and attach them at front side of the
engine compartment to eliminate the interference between the engine and hoses during lifting up the engine.
3. Remove the upper engine mounting insulator nuts (19mm) at both sides.
Installation Notice
Tightening torque
LH
70 7.5 Nm
RH
4. Raise the main lift and unscrew the four bolts (arrows) and two fasteners (1) to remove the skid plate.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-59
5. Place the rubber blocks under the oil pan (in front of the oil drain plug) and raise the engine with auxiliary lift.
Caution
The oil drain plug should be on the center point of the rubber block. Otherwise, the engine cannot be
raised properly due to the deviation of the center point of gravity.
Oil drain plug
6. Unscrew two engine mounting insulator bracket (RH) bolts and remove the bracket.
Installation Notice
Tightening torque
ENGINE HOUSING
DI ENG SM - 2004.9
25 2.5 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-60
7. Unscrew the power steering hose and pipe mounting bracket bolt from the engine mounting insulator bracket (LH)
and remove the bracket.
8. Remove two engine mounting insulator bracket bolts.
Installation Notice
Tightening torque
25 2.5 Nm
Power steering hose and pipe mounting bracket bolt (12mm)
Mounting bolt
(14mm)
Mounting bolt
(14mm)
9. Raise the main lift and lower the engine with the auxiliary lift until the distance between the oil pan and the sub
frame No.2 crossmember is 20mm. Make sure that there is no interference between components. If the engine is
lowered beyond the specified distance, the interference between the transmission oil cooler pipe and the front axle
can be occurred.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI02-61
10. Lower the main lift and remove the nut from brake booster vacuum hose.
11. Bring a torque wrench for vacuum pump and designated adaptor socket (special service tool).
Special service tool (Adaptor

socket for vacuum pump)
(Tightening torque: 4~12 Nm)
within 190 mm
12. Working position

The service personnel should work from the left side of the vehicle as shown in the figure. When removing the
vacuum pump mounting bolt (RH), move to the right side of the vehicle.
ENGINE HOUSING
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI02-62
13. Install the vacuum pump with the specified tightening
torque.
Installation Notice
Tightening torque
10 1 Nm
14. To align the camshaft and protrude section of the vacuum

pump, use the miiror as shown in the figure.
16. After installation, check the vacuum pump for leaks while
changing the engine speed for 2 minutes.
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AFFECTED VIN
ENGINE HOUSING
DI ENG SM - 2004.9
DI03-1
SECTION
00 DI03
INTAKE SYSTEM
Table of Contents
AIR FLOWS ................................................................. DI03-2
INTAKE SYSTEM LAYOUT ......................................... DI03-3
Components locator ............................................... DI03-3
Tightening torque of intake system ........................ DI03-4
Air cleaner ............................................................... DI03-5
Air flow sensor
(hot film air mass sensor) ....................................... DI03-8
Intercooler ............................................................. DI03-12
Intake manifold assembly ..................................... DI03-16
INTAKE SYSTEM
DI ENG SM - 2004.9
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AFFECTED VIN
DI03-2
AIR FLOWS
Intake Valve
(in combustion chamber)
Intake Manifold
Air Cleaner
Turbo
Charger
Engine
HFM Sensor
Intake Air Outlet Hose
Intercooler
Intake Air Inlet Hose
Work Flow of Intake System

Air
Cleaner
CHANGED BY
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AFFECTED VIN
HFM
Sensor
Turbo
Charger
Intercooler
Intake
Manifold
Combustion
Chamber in
Engine
INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-3
INTAKE SYSTEM LAYOUT

COMPONENTS LOCATOR
INTAKE SYSTEM
DI ENG SM - 2004.9
Air cleaner
Intake manifold
HFM sensor
Intercooler
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AFFECTED VIN
DI03-4
TIGHTENING TORQUE OF INTAKE SYSTEM
There is a possibility that the clamps of intercooler and related intake hoses are disconnected by the pressure of turbo
charger, therefore it should be tightened with proper torque using torque wrench and ratchet.
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5 ~ 6 Nm
INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-5
AIR CLEANER
Cover
Element
Housing
Specifications
Element Type
Dry-Element Type
* Initial cleaning: 5,000 km, Clean or change every 10,000 km as required.
However, change every 30,000 km.
Service Interval
INTAKE SYSTEM
DI ENG SM - 2004.9
* If the vehicle is operated under severe condition (short distance driving, extensive
idling or driving in dusty condition): More frequent maintenance is required.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI03-6
Air Cleaner Element - Replacement

2. Loosen the locking clamp and remove the intake duct.
3. Unscrew the screws and remove the air cleaner cover.
4. Remove the air cleaner element. Clean or replace the

element as required.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-7
Air Cleaner Housing

- Removal and Installation
Preceding Work: Removal of air cleaner cover
1. Set aside the return hose and remove the coolant reservoir
bolts.
2. Remove the air cleaner housing bolts.

Air Cleaner Housing/Element - Check

1. Check the air cleaner body, cover and packing for
deformation, corrosion and damage.
2. Check the air duct for damage.
3. Check the air cleaner element for clogging, contamination

and damage. If the element is partially clogged, remove
the dust or foreign materials with the compressed air. If
the contamination is severe, replace it with new one. Also,
be careful not to contaminate during the replacement.
4. Check the air cleaner housing for clogging, contamination
and damage.
5. If the inside of housing is contaminated, remove the
contaminants.
Notice
When cleaning the air cleaner with compressed air,

direct the air from inside (engine) to outside (ambient
air). Otherwise, contaminants can get into the engine.
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI03-8
AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR)
Change history
inner tube added + grid (No.3)
added + sensing chip changed +
sensing section design changed
Results
Durability has enhanced 60
times (lab test results)
<CI type HFM sensor structure>

1. Plug-in sensor
7. Hybrid
2. Cylinder housing
8. Sensor
3. Protection grid
9. Mounting plate
4. Hybrid cover
10. O-ring
5. Measuring duct cover
11. Temperature sensor
6. Housing
Air flow sensor is locating on the air intake passage between air cleaner and intake manifold and measures air volume
flows to engine combustion chamber and intake air temperature.
And intake temperature sensor built-in the sensor detects intake temperature.
Internal circuit of the air flow sensor is being used to control the voltage value to control the temperature to maintain the
heating resistance (Rh) to 160C that is higher temperature than intake air temperature that is measured by resistance
(RI).
Temperature sensor of the heating resistance (Rh) is measured by resistance (Rs).
If temperature changes occur due to increasing/decreasing intake air volume, voltage of the heating resistance changes
to maintain the intake air temperature changes to set value (160C).
Control unit computes intake air volume based on voltage changes of heating resistance.
Intake air temperature is measured by NTC integrated in the sensor.
CHANGED BY
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-9
Intake air temperature sensor is a part of HFM sensor and a thermister and resister and detects air temperature
changes that flow into the engine. There occurs high resistance when temperature is low and low resistance when high
(NTC type).
ECU supplies 5 V to intake air temperature sensor and then measures voltage changes to determine the intake air
temperature. When air in the intake manifold is cold, the voltage is high and air is hot, the voltage is low.
The reason for using HFM sensor is that this sensor is most proper in controlling accurate air-fuel ratio to meet the legal
emission regulations. This sensor measures actual intake air mass into engine very accurately during specific instant
acceleration and deceleration, and determines engine loads and detects intake air pulsation and air flows.
Main functions of HFM sensor are:
Using for EGR feedback control
Using for turbocharger booster pressure control valve control
Using for fuel injecting compensation
CI type HFM sensor: The air flowing the sensor does not directs toward sensing section but flows along with lower wall
after passing protection grid to enhance durability of the sensor. Oil, water and dust less damage the sensor.
Air outlet
Air inlet
<Structure of CI type HFM sensor>
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI03-10
Power supply
Intake air
flow
sensor
Ground
Ground
Signal

sensor
HFM sensor
<Circuit diagram of HFM sensor>
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-11
HFM Sensor - Removal and Installation
HFM sensor

2. Loosen the clamps on the air cleaner and the turbo
charger and remove the duct.
3. Unscrew the bolts and remove the HFM sensor assembly.

Installation Notice
Tightening torque
4 ~ 5 Nm
4. Install the reverse order of removal.
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI03-12
INTERCOOLER
The turbo charger is designed to improve the engine power by introducing more air (oxygen) into the engine. However,
the intake air is heated (100 ~ 110C) during the compression process in turbo charger compressor and the density is
lowered.
The intercooler is the device which cools (50 ~ 60C) the air entering the engine. Colder air has more oxygen molecules
than warm air. Thus cooler air gives more power and better fuel economy.
1. Intercooler
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-13
Intercooler - Removal and Installation

1. Disconnect all wiring harnesses and related connectors from the front side of radiator assembly.
AQS sensor
Ambient temperature switch

[for FFH]
Ambient temperature
sensor
Connector
[for air conditioner]
Receiver drier
Electric fans
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI03-14
2. Remove the front end center member.
3. Remove the hood latch cable and remove the radiator support upper member.
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-15
4. Remove the intercooler inlet hose.
Tightening torque
5. Remove the intercooler outlet hose.

6 ~ 7 Nm
Tightening torque
6 ~ 7 Nm
6. Unscrew the bolts and remove the intercooler assembly.

INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI03-16
INTAKE MANIFOLD ASSEMBLY
Shape that delivers the required capacity of compressed air from turbo charger to inlet port
Optimized EGR gas mixture in inlet chamber
Maximized intake efficiency with helical and tangential inlet port
- Improving the swirl ratio in low and mid operating range
- Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range
Integrated inlet port and coolant outlet port
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-17

Intake manifold guide pin
Application
Installation of intake manifold
Y99220112B
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI03-18
Intake Manifold - Removal/Installation

1. Lift up the vehicle and remove the skid plate.
2. Open the coolant reservoir cap and remove loosen the

drain cock to drain the coolant.
3. Remove the air inlet hose (1) from intake manifold.

4. Loosen the clamp and remove the coolant inlet hose (2).
5. Remove the coolant inlet port housing.

6. Remove the vacuum hose from EGR valve.
7. Remove the EGR valve mounting bolts and gasket.
Remove the EGR exhaust pipe (primary) mounting bolts
and gasket.
Notice
Replace the pipes (2, 3) at both sides of EGR cooler

(1) and gaskets with new ones.
Make sure that the convex surface of gasket is facing
to the pressurized direction.
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI03-19
8. Remove the brackets and connectors from top section of
the engine.
- Vacuum hose bracket in turbo charger
- Booster pressure sensor
- Main wiring bracket
- Ground cable bracket
- Fuel pressure sensor connector
9. Unscrew the bolts and remove the vacuum modulator
bracket.
Installation Notice
Tightening torque
9.0 Nm
10. Remove the HP pump fuel supply line bolts.

11. Remove the HP pump fuel supply line mounting bracket.
12. Remove the HP pump fuel return line at fuel filter.
Notice
Plug the openings of pipes and ports with sealing

caps to keep the cleanness of the fuel system.
Replace the pipes with new one once removed.
13. Remove the injector return line at HP pump.

Notice
Be careful not to damage the pipes to HP pump.

Plug the fuel return port of the HP pump with a
sealing cap.
INTAKE SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI03-20
14. Remove the intake manifold mounting bolts.
Installation Notice
Tightening torque
25 2.5 Nm
Check the length of the bolts before installation.
M8 x 45: 6EA
M8 x 130: 6EA
15. Lift up the vehicle and remove the propeller shaft joint
bolts.
16. Unscrew the bolt in oil filter and remove the intake
manifold and gasket.
Notice
Replace the gasket with new one.
Make sure that the residual coolant in intake
manifold gets into the inside of inlet port.
Notice
If replaced only gasket without any other service
operation, completely remove the coolant and other
contaminants from the engine before installation.
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INTAKE SYSTEM
DI ENG SM - 2004.9
DI04-1
SECTION
00 DI04
EXHAUST SYSTEM
Table of Contents
EXHAUST SYSTEM LAYOUT ..................................... DI04-2
Components locator ............................................... DI04-2
Exhaust gas flows ................................................... DI04-3
Turbo charger assembly ......................................... DI04-5
EGR VALVE AND VACUUM MODULATOR ............... DI04-26
EGR system .......................................................... DI04-26
EGR valve and turbo charger actuator
control vacuum circuit ........................................... DI04-27
EXHAUST SYSTEM AND MUFFLER ........................ DI04-35
Muffler ................................................................... DI04-35
System overview ................................................... DI04-36
EXHAUST SYSTEM
DI ENG SM - 2004.9
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DI04-2
EXHAUST SYSTEM LAYOUT

COMPONENTS LOCATOR
Muffler
Turbo charger
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Catalytic converter (DOC)
Exhaust manifold
EGR valve
EGR pipe
Vacuum modulator
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-3
EXHAUST GAS FLOWS

Catalytic
converter
Exhaust
pipe
Muffler
Atmosphere
Exhaust gas
Turbo charger
(turbine side)
EGR vacuum
modulator
To turbo
charger booster
Turbo charger
booster vacuum
modulator
Turbo charger
booster
EGR valve
Exhaust manifold
Blow-by gas
EGR pipe
Engine
-Combustion
Chamber-
Exhaust
Manifold
Turbo
Charger
EGR Valve
EXHAUST SYSTEM
DI ENG SM - 2004.9
Exhaust
Muffler
Atmosphere
Intake
Manifold
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AFFECTED VIN
DI04-4
Exhaust Manifold
1. Remove the two intake hoses from the turbo charger.
2. Remove the turbo charger assembly (refer to Turbo

Charger section).
3. Remove the #3 pipe of EGR valve from the exhaust

manifold.
Installation Notice
Tightening torque
35 3.5 Nm
The #3 pipe of EGR valve is exposed to the high

temperature and pressure of exhaust gas. Replace
the gasket and pipe with new ones. Otherwise, it
may cause the leakage of exhaust gas.
4. Unscrew the nuts and remove the exhaust manifold and

gasket.
Installation Notice
Tightening torque
40 4.0 Nm
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-5
TURBO CHARGER ASSEMBLY

The turbo charger is an air pump installed on the intake manifold. It enhances power and increases torque power of
engine to increase the fuel consumption rate. The engine without turbo charger cannot get as much power output as it
inducts air by the means of vacuum being generated from descending strokes of the piston. Therefore, by installing the
turbo charger on the intake manifold, it supplies great amounts of air to the cylinder increasing the volume efficiency
and, subsequently, enhances output power.
Also, as the engines power enhances, it increases the torque power and improves the fuel consumption rate. The
regular turbo charger operates by utilizing the pressure from the exhaust gas and the other, called Super Charger,
operates by utilizing power from the engine. When the turbo charger is installed, weight of the engine increases by 10
to 15 % whereas the output power increases by 35 to 45 %.
Operating Principle of Turbo Charger

The turbo charger has one shaft where at each ends are installed with two turbines having different angles to connect
one end of housing to the intake manifold and the other end to
the exhaust manifold. As the turbine, at exhaust end, is rotated by exhaust gas pressure the impeller, at intake end,
gets rotated to send air around center of the impeller, being
circumferentially accelerated by the centrifugal force, into the
diffuser.
The air, which has been introduced to the diffuser having a
passage with big surface, transforms its speed energy into
the pressure energy while being supplied to the cylinder improving the volume efficiency. Also, the exhaust efficiency
improves as the exhaust turbine rotates. The turbo charger is
often referred to as the exhaust turbine turbo charger.
Turbine
Impeller
Intercooler
Intake
Exhaust
Intercooler
coolant
Diffuser: With the meaning of spreading out it is a device that

transforms fluids speed energy into the pressure energy by
enlarging the fluids passage to slow down the flow.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-6
Construction of Turbo Charger

The turbine wheel in turbo charger and compressor wheel are installed at each side of the shaft. It is comprised with the
shaft supporting center housing (supporting the compressor with two float journal bearings), the turbine side parts of
turbine wheel, shroud and turbine housing, and the compressor side parts of compressor wheel, back plate and compressor housing.
The turbine rotates turbine wheel by receiving exhaust gas energy from the engine.
The compressor receives torque energy from the turbine and the compressor wheel inducts air to force it inside of
the cylinder.
1. Turbine housing
A. Air inlet (from atmosphere)
2. Turbine wheel
B. Air flow
3. Compressor housing
C. Exhaust gas inlet (from cylinder)
4. Compressor wheel
D. Exhaust gas outlet (to atmosphere)
5. Center housing
E. Exhaust gas bypass passage
6. Turbo charger booster pressure control valve
H. Oil supply opening
7. Control link
J. Oil return line
8. Bypass flap
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-7
Impeller
Turbine
Impeller
The impeller is wings (wheel) installed on the intake end and

performs the role of pressurizing air into the cylinder.
Turbine shaft
Thrust collar
The radial type has the impeller plate arranged in straight line
at the center of shaft and, compared to the backward type, is
being widely used as it is simple, easy to manufacture and
appropriate for high speed rotation. As the impeller rotates in
the housing with the diffuser installed in it, the air receives
centrifugal force to be accelerated in the direction of housings
outer circumference and flows into the diffuser.
As surface of the passage increases, air flown into the diffuser transforms its speed energy into pressure energy and
flows into the intake manifold where the pressurized air is
supplied to cylinder each time the intake valve of cylinder opens
up. Therefore, the efficiency of compressor is determined by
the impeller and diffuser.
Floating bearing
Turbine
Impeller
Exhaust gas
Diffuser
Oil passage
Turbine
The turbine is wings installed at the exhaust end where, by the pressure of exhaust gas, it rotates the compressor and
performs the role of transforming heat energy of exhaust gas into torque energy. The radial type is used as the turbines
wings. Therefore, during operation of the engine, the turbine receives temperature of exhaust gas and it rotates in high
speed, it requires to have sufficient rigidity and heat resisting property.
During operation of the engine, exhaust gas discharged through the exhaust valve of each cylinder makes turbine rotate
by coming in contact with the turbines wings from the outer circumference within housing of the turbine and is exhausted through the exhaust manifold. At the same time, as the impeller is on the same shaft, it rotates.
Floating Bearing
Floating Bearing is a bearing, which supports the turbine shaft that rotates at about 10,000 to 15,000 rpm. It could be
rotated freely between the housing and the shaft as it gets lubricated by oil being supplied from the engine.
Notice
Stopping the engine immediately after driving at high speed stops oil from being supplied to the bearing and
may cause it to get burnt. Therefore, the engine must be stopped after cooling the turbo system by sufficiently
idling the engine.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-8
Booster Pressure Control Valve Unit (Turbo Charger Actuator)

In order to reduce discharging of hazardous exhaust gas and to avoid the engines overrun the turbo charger must be
appropriately controlled. The maximum turbo charging pressure must be controlled as excessive increase in the pressure and power output can cause critical damages to the engine. In order to control these, the booster pressure control
valve is installed on the turbo charger.
The difference of the booster pressure control between the existing IDI engine and DI engine is that in IDI engine, booster
pressure of the intake manifold operates the booster pressure control valve connected directly to the turbo charger
whereas in DI engine, the control is achieved by utilizing vacuum modulator (vacuum from a vacuum pump) designed to
control the booster pressure control valve. It operates booster pressure control valve by supplying electrical power to the
vacuum modulator having the amount of air being flown into the HFM sensor from the engines ECU as the base signal.
Refer to the EGR section in following pages for the function of turbo charger and HFM sensor in exhaust system.
Booster pressure control valve unit and vacuum modulator
Turbo charger booster
Turbo charger booster

vacuum modulator
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-9
Diagnosis and Maintenance for Turbo Charger System

Cautions During Driving
The following lists cautions to take during test drive and
on the turbo charger vehicle, which must be considered
during the operation;
1. Its important not to drastically increase the engine
rpm starting the engine. It could make rotation at
excessive speed even before the journal bearing is
lubricated and when the turbo charger rotates in poor
oil supply condition, it could cause damage of bearing
seizure within few seconds.
2. If the engine is running radically after replacing the
engine oil or oil filter brings poor oil supply condition.
To avoid this, its necessary to start off after idling
the engine for about 1 minute allowing oil to circulate
to the turbo charger after the replacement.
3. When the engine is stopped abruptly after driving at
high speed, the turbo charger continues to rotate in
condition where the oil pressure is at 0. In such
condition, an oil film between the journal bearing and
the housing shaft journal section gets broken and
this causes abrasion of the journal bearing due to the
contact of metal parts. The repeat of such condition
significantly reduces life of the turbo charger.
Therefore, the engine should be stopped possibly in
the idle condition.
Notice
After string for long period of time during winter

season or in the low temperature condition where
the fluidity of engine oil declines, the engine,
before being started, should be cranked to
circulate oil and must drive after checking the oil
pressure is in normal condition by idling the
engine for few minutes.
EXHAUST SYSTEM
DI ENG SM - 2004.9
Inspection of Turbo Charger

When problem occurs with the turbo charger, it could cause
engine power decline, excessive discharge of exhaust gas,
outbreak of abnormal noise and excessive consumption
of oil.
1. Inspection when installed
- Check the bolts and nuts for looseness or missing
- Check the intake and exhaust manifold for
looseness or damage
- Check the oil supply pipe and drain pipe for
damages
- Check the housing for crack and deterioration
2. Inspection of turbine in turbo charger
Remove the exhaust pipe at the opening of the turbine
and check, with a lamp, the existence of interference
of housing and wheel, oil leakage and contamination
(at blade edge) of foreign materials.
- Interference: In case where the oil leak sign exists,
even the small traces of interferences on the
turbine wheel mean, most of times, that abrasion
has occurred on the journal bearing. Must inspect
after overhauling the turbo charger.
- Oil Leakage: Followings are the reasons for oil
leakage condition;
Problems in engine: In case where the oil is
smeared on inner wall section of the exhaust
gas opening.
Problems in turbo charger: In case where the
oil is smeared on only at the exhaust gas
outlet section.
Notice
Idling for long period of time can cause oil

leakage to the turbine side due to low pressure of
exhaust gas and the rotation speed of turbine
wheel. Please note this is not a turbo charger
problem.
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DI04-10
- Oil Drain Pipe Defect
In case where oil flow from the turbo charger
sensor housing to the crank case is not smooth
would become the reason for leakage as oil builds
up within the center housing. Also, oil thickens
(sludge) at high temperature and becomes the
indirect reason of wheel hub section. In such case,
clogging and damage of the oil drain pipe and the
pressure of blow-by gas within the crank case
must be inspected.
- Damages from Foreign Materials
When the foreign materials get into the system,
it could induce inner damage as rotating balance
of the turbo charger gets out of alignment.
Inspection of Turbine
Thoroughly check the followings.
Notice
Must absolutely not operate the turbo charger with the

compressor outlet and inlet opened as it could damage
the turbo charger or be hazardous during inspection.
- Interference: In case where is trace of interference or
smallest damage on the compressor wheel means,
most of times, that abrasion has occurred on the
journal bearing. Must inspect after the overhaul.
- Oil Leakage: The reason for oil leakage at the
compressor section is the air cleaner, clogged by
substances such as dust, causes the compressor
inlet negative pressure;
A. Rotating in high speed at no-load for extended
period of time can cause oil leakage to the
compressor section as oil pressure within the
center housing gets higher than pressure within
the compressor housing.
B. Overuse of engine break (especially in low gear)
in down hill makes significantly low exhaust gas
energy compared to the time where great amount
of air is required during idling conditions of the
engine. Therefore, amount of air in the
compressor inlet increases but the turbo charge
pressure is not high, which makes negative
pressure at the compressor section causing the
oil leakage within the center housing.
Notice
No problem will occur with the turbo charger if

above conditions are found in early stage but oil
leaked over long period of time will solidify at
each section causing to breakout secondary
defects.
- Damages by foreign materials: In case where the
compressor wheel is damaged by foreign materials
requires having an overhaul. At this time, its
necessary to check whether the foreign materials have
contaminated intake/exhaust manifold or inside of
engine.
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-11
Path of Turbo Charger Defect
The following tries to understand the defects that can occur with vehicle installed with the turbo charger and to manage
the reasons of such defects.
1. In case where oil pan/oil pipe has been contaminated, oil filter is defected and where
adhesive of gaskets has been contaminated into the oil line.
Contamination of Oil
Journal Bearing
Damage or Wear
Clogging of Oil
Passage
Metal Contact
Poor Oil Supply
Shaft Journal Bearing Wear
Rotor Wear
Seal Wear at
Exhaust System
Seal Wear at Intake

System
Interference of
Turbine and Compressor Components
Oil Leakage
Abnormal Noise
Check Booster Pressure

Control Valve
EXHAUST SYSTEM
DI ENG SM - 2004.9
Lack of Power/Poor
Acceleration (Lack of
Turbo Charged Pressure)
Check Exhaust Gas Pipes
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AFFECTED VIN
DI04-12
2. Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of oil
line.
Poor Oil Supply
Metal Contact of Shaft /Journal Bearing/

Center Housing Inner Part
Journal Bearing/Center Housing Inner Part

Wear/Seizure
Melt down of Bearing to Turbine Wheel Journal
Rotor Rotational Movement
Seal Wear at Exhaust

System
Seal Wear at Intake

System
Interference of Turbine and

Compressor Components
Abnormal Noise
Lack of Power/Poor
Acceleration (Lack of
Turbo Charged Pressure)
Oil Leakage
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EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-13
3. Turbine Side: Inflow of foreign materials from engine
Compressor Side: such as air filter, muffler and nut
Inflow of Foreign Materials

into Turbine

into Compressor
Shaft Wheel Blade Break
Compressor Wheel Blade

Break
Unbalancing Rotor Rotation
Rotor Bearing Wear
Rotor Turning Movement
Seal Wear at Exhaust

System
Seal Wear at Intake

System
Interference of Turbine and

Compressor Components
Abnormal Noise
Lack of Power/Poor Acceleration (Lack of Turbo

Charged Pressure)
Oil Leakage
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI04-14
4. Defects caused by reasons other than that of the Turbo Charger.
Oil Leakage at Turbine
<In case where the scanner

displays as electrical malfunction>
Excessive Engine Wear
Dampness or Poor Connection of Turbo Charger Actuator
Connecting Vacuum Circuit
No Problems in Turbo
Charger System
Excessive Inflow of Blow-By

Gas, Idling at Low Speed,
Clogging of Oil Drain Pipe
Oil Leakage at Seal
Oil Leakage at Turbine

Housing Entrance
Misunderstanding of Oil
Leakage
<Mechanical
Malfunction>
Detection of DTC Code

Caused By HFM Sensor or
EGR Valve Malfunction
Vacuum Modulator Power

Control Error for Controlling
Actuator in Engine ECU
Carbonization Caused By
High Temperature
Seal Wear
Oil Leakage
Oil Leakage at Compressor
Inflow of Dust
Increase of Negative Pressure

Increase at Inlet Side
Oil Leak Sign at Compressor Inlet and Outlet
Excessive Inflow of Blow-By

Gas, No-Load High Speed
Rotation
Misunderstanding of Oil
Leakage
No Problems in Turbo
Charger System
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AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-15
How to Diagnose
The followings are cautions to take in handling defects of turbo charger, which must be fully aware of;
Cautions When Examining the Defects:
1. After stopping the engine, check whether the bolts on pipe connecting section are loose as well as the connecting
condition of vacuum port and modulator, which is connected to the actuator.
2. During idling of the engine, check for leakage in the connecting section of pipe (hoses and pipes, duct connections,
after the turbo charger) by applying soap water. The leakage condition in the engine block and turbine housing
opening can be determined by the occurrence of abnormal noise of exhaust.
3. By running the engine at idle speed, abnormal vibration and noise can be checked. Immediately stop the engine
when abnormal vibration and noise is detected and make thorough inspection whether the turbo charger shaft
wheel has any damages as well as checking the condition of connections between pipes.
4. In case where the noise of engine is louder than usual, there is possibility of dampness in the areas related with air
cleaner and engine or engine block and turbo charger. And it could affect the smooth supply of engine oil and
discharge.
5. Check for damp condition in exhaust gas when there is sign of thermal discoloration or discharge of carbon in
connecting area of the duct.
6. When the engine rotates or in case where there is change in noise level, check for clogging of air cleaner or air
cleaner duct or if there is any significant amount of dust in the compressor housing.
7. During the inspection of center housing, inspect inside of the housing by removing the oil drain pipe to check for
sludge generation and its attachment condition at shaft area or turbine side.
8. Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign materials.
9. Inspect both side of the turbo charger wheel after removing inlet and outlet pipe of the turbo charger.
- Is the rotation smooth when the rotor is rotated by hand?
- Is the movement of bearing normal?
- Inspect whether there has been any signs of interference between two wheels.
Notice
Its important not to drive the engine when the intake manifold hose has been removed.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI04-16
Diagnosis and Measure
Poor Engine Power or Smoke Discharge
Air Cleaner Contamination

and Clogging of Oil Pass
Type Air Cleaner
NO
YES
Slack between Compressor Entrance and Exhaust

Manifold Connection
NO
YES
Replace Air Cleaner

Element or Oil Pass Type
Air Filter
Leaks at Intake Manifold

YES
Inspect and Repair

Intake Manifold
Reconnect Connections
NO
Leaks at Exhaust Manifold
NO
Leaks at Turbo Charger

Connecting Flange
NO
YES
Poor Rotation or Interference of Turbo Charger

Components
YES
Inspect and Repair Intake

Manifold
Refer to Diagnosis
Table
NO
Clogging Between Air

Cleaner and Compressor
NO
YES
Clogging Between Compressor Exit and Intake

Manifold
YES
Clean or Replace Affected

Components

Components
NO
Clogging of Engine Muffler

YES
Clean or Replace
Affected Components
NO
Clogging of Engine Intake/

Exhaust Manifold
YES
Inspect and Repair
Related Components
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
NO
Weakness of Engine
Function, Intake/Exhaust
Valve Damage, Timing
Defects of Each Valve
YES
Inspect and Repair
Related Components
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-17
Before Diagnosis
The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in
related system as the first priority. When abnormal condition occurs with the EGR system, the basic approach is, as
described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the scan
tool or vacuum tester. It is necessary to manually check on the connections if there are any slacks or loose circuits even
if the visual inspection shows vacuum hose as being connected. If there are not any problems then the next inspection
area is the connections of the system connectors. Most problems with the occurrence of system malfunction are from
conditions of vacuum line and connector connections and the causes from the malfunction of mechanical mechanism is
actually very few.
For example, when there are no problems with basic components, lets assume that there is a vehicle having vacuum
leak from connection slack in the vacuum line between EGR vacuum modulator and EGR valve. This vehicle, due to the
driving condition or, according to the circumstances, smog or other conditions, could create customers complaint and
by connecting the scanning device could display as the malfunction of the EGR valves potentiometer.
As previously explained, this car has a separate controller to control the HUBER EGR and, in accordance with various
input element, the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through
PWM control. At this time, the controller has to receive feedback whether the EGR valve operates correctly according to
the value sent to the EGR modulator and this role is performed by the EGR potentiometer located at top section of the
EGR valve.
In other word, the controller sent correct output value to the EGR vacuum modulator but, due to the leakage of vacuum,
signal of required value can not be received from the EGR potentiometer causing to display as malfunction of related
parts.
As a reference, the EGR valve of diesel vehicle (DI Engine) controlling from the engine ECU to EGR system has different
shape than the HUBER EGR valve because the EGR valves operation signal in the DI engine is performed by the HFM
sensor instead of the EGR potentiometer.
This principle is that when the EGR valve opens up to flow exhaust gas into the intake unit the amount of fresh air,
comparatively, will be reduced. The DI engine ECU receives feedback signal of change in amount of air being passed
through the HFM sensor according to the opening amount of the EGR valve.
HUBER EGR System for IDI Engine
EGR System for DI Engine
(Including the EGR Valve Potentiometer)
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-18
The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum modulator,
one is same as being the modulator for EGR valve whereas the HUBER EGR systems the other modulator controls
ALDA of injection pump and the DI engines the other modulator controls waist gate of the turbo charger.
This difference is in accordance with the difference in fuel injection method where the IDI engine has mechanical
injection system and DI engine is capable of making electronically controlled fuel injection.
In other word, to reduce the amount of the fuel injection in no-load rapid acceleration mode, the IDI engines HUBER
EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative
pressure to occur in the vacuum modulator to reduce the amount of fuel injection. When DI engine, basing input signal
from the related sensors such as acceleration pedal sensor and engine RPM, recognizes that current mode is the noload rapid acceleration mode it reduces the amount of fuel injection by sending short electrical signal to the injector.
Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other modulator is
used to control the booster pressure valve in turbo charger.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-19
When Engine Exhaust Gas shows White Smog or
Blue Smog
Poor Connection between

Compressor Outlet and
Intake Manifold
NO
Oil Leak Sign around

Intake Manifold
YES
NO
YES
Reconnection
Clogging of Engine Oil

Element
YES
Inspect PVC Line
Replace Oil Filter
NO
Clogging or Damage
between Air Cleaner and
Turbo
NO
Oil Leakage at Seal

between Turbo Charger
and Compressor
YES
NO
YES
YES

Components
Engine Malfunction (Ring,

Piston, Valve)
Repair (overhaul)
Engine
Refer to Diagnosis Table
Excessive Consumption of Engine Oil
Improper Inspection of Air

Cleaner Contamination
NO
YES
Improper Viscosity of
Engine Oil Being Used
YES
Replace Air Cleaner

Element
Replace with Specified Oil
NO
Poor Oil Seal at Turbo

Compressor Side (Oil leak
sign at housing and wheel)
YES
Refer to Diagnosis
Table
NO
Poor Oil Seal at Turbo Turbine
Side (trace of leakage in
housing and wheel)
YES
EXHAUST SYSTEM
DI ENG SM - 2004.9
NO
Oil Leakage at Engine

Exhaust Manifold (damages
to ring, piston and valve)
YES
Inspect or repair Manifold
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-20
Abnormal Noise from Turbo Charger System
Contamination or Clogging
of Air Cleaner
NO
YES
Leaks at Pipe and Hose

Duct Parts between
Manifolds of Turbo Charger
NO
YES
Clean or Replace If
required
Inflow of Foreign Material

to Compressor Entrance
or Housing
YES
Inspect and Repair Air
Cleaner Element and Turbo
Charger after Removing
Foreign Materials
Inspect or Replace
Connections
NO

to Intake Manifold
YES
Inspect and Repair Air
Cleaner Element and Turbo
Charger after Removing
Foreign Materials
NO

to Muffler
YES
Repair Muffler and Turbo

Charger After Removing
Foreign Materials
NO
Poor Rotation of Rotating

Turbo Charger Components and Interference
YES
Repair Housing and
Turbo Charger and
Inspect Normal Operation for Engine
NO
Check the Interference
between Rotating Turbo
Charger Components and
Housing
YES
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-21
Poor Rotation of the Turbo Charger
Compressor Wheel
Damages By Inflow of
Foreign Material
NO
Turbine Wheel Damages

By Inflow of Foreign
Material
YES
NO
YES
Repair or Replace Air

Cleaner Element and
Turbo Charger
Interference of Compressor Wheel with Housing

YES
Fatigue and Wear in
Bearing or Shaft
Journal (Refer to
Diagnosis Table)
Repair or Replace Exhaust Manifold
NO
Clogging of Compressor
by Dust
NO
Excessive Deposit of
Carbon or Combustion
Residues Inside of Turbine
Wheel by Oil Contamination
NO
Gel Type Oil in Center

Housing
YES
YES
YES
Repair or Replace Turbo

Charger
Repair or Replace Air

Cleaner Element and
Turbo Charger
Repair or Replace Engine

Oil Filter and Turbo
Charger
Oil Leakage at Turbine in Turbo Charger
Excessive Filling of Oil

When Installing
NO
YES
Clogging of Oil Drain

Pipes in Turbo Charger
YES
Oil Disappears After

Combustion
Clean or Replace Drain

Line
NO
Gel Type Oil in Center

Housing or Excessively
Contaminated Oil
YES
Repair or Replace
Engine Oil Filter and
Turbo Charger
NO
Deterioration of Turbo
Charger Journal
YES
EXHAUST SYSTEM
DI ENG SM - 2004.9
NO
Poor Engine Function

(Too High Blow-by gas
pressure in crankcase)
YES
Inspect PVC Line
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-22
Oil Leakage at Compressor in Turbo Charger
Contamination of Air
Cleaner Element
NO
YES
Too High Oil Viscosity
NO
YES
Clean or Replace Air

Cleaner Element
Clogging or Damage of
Pipe between Air Cleaner
and Turbo Charger
YES
Replace Damaged
Components after
Cleaning clogged Area
Replace With Specified

Oil
NO
Looseness in Connection
between Compressor
Outlet and Intake Manifold
NO
YES
Oil Leakage at Intake

Manifold
NO
YES
Reconnect After Inspection
Clogging of Oil Drain Pipe

in Turbo Charger System
YES
Inspect and Repair Intake

Manifold
Clean Clogged Area

After Inspection
NO
Deterioration or Damage
to Compressor Wheel
YES
Clean, Repair or Replace
Air Cleaner Element and
Turbo Charger
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
NO
Clogging Between Compressor Outlet and Intake

Manifold
YES
NO
Clogging of Engine Muffler

YES
Inspect PCV Line
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-23
Wear in Turbo Charger Inner Diameter and
Shaft Journal
Poor Oil Filling When

Installing or Replacing
Turbo Charger
NO
Contamination of Oil Filter

or Use of Low Grade Oil
YES
NO
Lack of Oil in Turbo

Charger
YES
YES
Clean or Replace Air

Cleaner Element / Replace With Specified Oil
Reinstall While Using

Specified Oil
Add Oil During Idling
NO
Poor Oil Supply by
Clogging of Oil Supply
Pipe in Turbo Charger
NO
Clogging of Engine Oil

Filter
YES
Clean and Repair Damaged Components
NO
Wear in Journal Section

By Clogging in Center
Housing
YES
YES
Replace Oil Filter
Repair or Replace
Turbo Charger
NO
Poor Function of Engine
Oil Pump
YES
Inspect and Replace If
Required
For other diagnosis, refer to Diagnosis section.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-24
Turbo Charger Assembly

1. Remove the drain plug and drain the engine oil from the
oil pan.
Installation Notice
Tightening torque
25 2.5 Nm
2. Remove the vacuum hose and inlet hose from the turbo
charger.
Installation Notice
Tightening torque
6 ~ 7 Nm
3. Remove the bolts and nuts at the exhaust manifold in

turbo charger.
Installation Notice
Tightening torque
25 2.5 Nm
4. Remove the lower and upper bolts at turbo charger oil

supply pipe.
Installation Notice
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
23 2.3 Nm
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-25
5. Remove the lower bolts at turbo charger oil return pipe.
Installation Notice
Tightening torque
25 2.5 Nm
Replace the steel gasket with new one.
6. Remove the lower bolt at turbo charger bracket.

7. Remove the turbo charger bracket bolts.
Installation Notice
Tightening torque
32 3.2 Nm
Use only 12 1/2" wrench.
8. Remove the bolts and nuts at the turbo charger and the
exhaust manifold.
Installation Notice
Tightening torque
25 2.5 Nm
9. Remove the turbo charger assembly.

Notice
Replace the steel gasket with new one.
To prevent gas leaks, tighten the fasteners with the
specified tightening torques.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-26
EGR VALVE AND VACUUM MODULATOR

EGR SYSTEM
General Information
EGR system controls the opening value of EGR valve by transmitting electrical signal (PWM control) from the engine
ECU to vacuum modulator. Also, the engine ECU receives the feedback signals of the amount of air flowing through the
HFM sensor.
Various sensor
Signals
1. EGR valve
4. EGR center pipe (EGR cooler)
2. Vacuum modulator
5. Intake manifold
3. Vacuum pump
6. HFM sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-27
EGR VALVE AND TURBO CHARGER ACTUATOR CONTROL VACUUM

CIRCUIT
Vacuum Modulator
The biggest difference between the vacuum circuit and layout of the HUBER EGR system after K2004 has been introduced is the location of the vacuum modulator for EGR valve control and the function of the other modulator. In case of
EGR equipped vehicle (IDI Engine), it performs the role of controlling the PLA of injection pump whereas, in DI engine, it
controls the turbo charger actuator.
DI engine vacuum modulator

2. Turbo charger booster vacuum modulator
From vacuum pump
To EGR Valve
To turbo charger
actuator
Vacuum pump
1. Vacuum modulator for EGR valve control

2. Vacuum modulator for injection pump PLA control
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-28
Vacuum Modulator and Vacuum Hose

Below figures illustrate vacuum hoses and related parts of EGR or turbo where wrong or poor connection of vacuum hose
would display condition of engine irregularity and defect diagnostic codes on the scan tool.
Related with EGR valve
From vacuum pump

EGR valve
Vacuum modulator for

EGR valve control
Related with turbo charger actuator
Turbo charger pressure valve
Vacuum modulator for turbo

charger booster control
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
From vacuum pump
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-29
EGR System Diagram
Intercooler
Exhaust
manifold
Intake
manifold
EGR
valve
Regulated
vacuum
pressure
Modulator
Vacuum
pump
Duty
control
Feedback EGR
(Air Mass)
ECU
Improved target EGR
Pedal
signal
Air intake signal

(for EGR feedback control)
Turbo charger
RPM
signal
EGR Valve
EGR valve recirculates some of exhaust gases to intake system to reduce toxic NOx from engine according to ECU
signals.
EGR valve opening point : -270 mmHg
EGR Modulator
According to ECU signals, the vacuum modulator drives EGR valve by controlling vacuum pressure that is generated by
vacuum pump with PWM type controls.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-30
Operation Principle of Vacuum Modulator

Vacuum pump
Output vacuum
ATM
Plunger
Connector
Vacuum control
Diaphragm
Seat assembly
Spring
Atmospheric pressure
Plunger
Air flow
During duty increase (B)
During duty reduction (C)
Vacuum is controlled according to relationship between chamber pressure (I) in rolling nipple cover and magnetic
force (II) in plunger.
According to ECU signals, the solenoid valve controls the vacuum pressure that is generated by vacuum pump (-900
20 mbar) with PWM type control and drives the mechanical EGR valve and turbo charger.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-31
Operating principle: Balance between original vacuum pressure and magnetic force (see above figure)
Normal state (Fig. A): Original vacuum and seat section, 3 stoppers keep sealing
Duty up state (Fig. B): Original vacuum pressure is connected to inside of diaphragm chamber
Duty down state (Fig. C): Increased diaphragm chamber pressure is connected to atmosphere to compensate the
pressure.
Floating plunger
Stroke
(mm)
Max. Distance
1mm
DUTY 50%
Output C/V
Operating principles when duty is applied from 0 to 50 %
Vacuum consumption: Compared to 50 % of duty, ON/OFF periods are most unstable and vacuum
consumption is most high.
Flowing
volume
Output vacuum (-mmHg)
Output Characteristics
EXHAUST SYSTEM
DI ENG SM - 2004.9
Up
Down
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-32
Operating Conditions
Engine is running
Engine RPM is within a specified range. (EGR OFF under high RPM range)
Engine torque is within a specified range. (EGR OFF under high torque range)
Vehicle speed is within a specified range. (EGR OFF under high speed range)
Atmospheric pressure is within a specified range. (EGR OFF under high altitude and low atmospheric pressure)
Coolant temperature is within a specified range. (EGR OFF under high or low temperature)
EGR OFF under extended period of idling.
Control Logic
Main map: EGR volume is controlled based on intake air volume
Auxiliary map
- Coolant temperature (Coolant temperature sensor)
- Engine rpm (Crankshaft position sensor)
- Engine load (TPS): Detection of sharp acceleration
- Intake air temperature (HFM): Decreases when over 60C
- Atmospheric pressure (Barometric sensor): Compensation of altitude
Compensation value of auxiliary map will be increased/decreased based on main map then ECU calculates EGR
volume finally to regulate the vacuum duty that applies to the vacuum modulator to control EGR valve openings.
Shut-off Conditions
Engine rpm: over 2,950 rpm
Vehicle speed: over 105 km/h
Coolant temperature: over 100C or below 10C
Idle period: over 50 seconds
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-33
EGR Valve and Pipe

1. Remove the vacuum hose from the EGR valve.
2. Unscrew the bolts and remove the EGR valve (2), EGR
valve #1 pipe (1) and gasket.
Installation Notice
Tightening torque
25 2.5 Nm
3. Remove the EGR valve #1 pipe, #2 pipe, #3 pipe and

gaskets from the engine.
Installation Notice
Tightening torque
25 2.5 Nm

Notice
Make sure to observe the specified tightening

torques.
EGR #3 pipe (LH)

EGR #1 pipe (RH)
EGR center pipe
Never reuse the EGR #1 pipe (intake) and #3 pipe

(exhaust) once removed.
Replace the gaskets with new ones.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-34
Vacuum Modulator
1. Remove the vacuum hose from the vacuum modulator.
2. Remove the vacuum modulator from the bracket.

Installation Notice
Tightening torque
10 1.0 Nm

Notice
Make sure that the vacuum hoses are connected to

correct locations.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-35
EXHAUST SYSTEM AND MUFFLER

Heat shield
#3 Hanger
#2 Hanger
Muffler
Heat shield
#1 Hanger
Muffler
DOC (Diesel Oxidation Catalyst)
#1 Pipe
Muffler
Tail pipe
MUFFLER
The muffler is located at the middle of the exhaust pipe and reduces the pulse noise and the tail pipe noise by eliminating
the flowing resistance from the exhaust gas.
The important elements of the muffler are volume, construction and location.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-36
SYSTEM OVERVIEW
Exhaust System
Check the complete exhaust system and the nearby body
areas and trunk lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose
connections, or other deterioration which could permit
exhaust fumes to seep into the trunk may be an indication
of a problem in one of these areas. Any defects should be
corrected immediately.
Notice
When you are inspecting or replacing exhaust system

components, make sure there is adequate clearance
from all points on the underbody to avoid possible
overheating of the floor panel and possible damage to
the passenger compartment insulation and trim
materials.

DOC (Diesel Oxidation Catalyst) is the purification device
to reduce the toxic emissions from the exhaust gas from
the engine. By using the chemical reaction, the amount of
toxic gas such as NOx can be reduced.
Muffler
Aside from the exhaust manifold connection, the exhaust
system uses a flange and seal joint design rather than a
slip joint coupling design with clamp and U-bolts. If hole,
open seams, or any deterioration is discovered upon inspection of the front muffler and pipe assembly, the complete assembly should be replaced. The same procedure
is applicable to the rear muffler assembly. Heat shields for
the front and rear muffler assembly and catalytic converter
protect the vehicle and the environment from the high temperatures that the exhaust system develops.
Heat Shield
The heat shield protects the vehicle and components from
the high heat generated from the exhaust system.
In this vehicle, the heat shield to block the heat from DOC
is installed to the underbody, and the heat shield to block
the heat from the rear muffler is installed to the underbody
between the fuel tank and the rear muffler.
Hanger
The hanger is to support the components.
Notice
To prevent damage of DOC, never contact the lift pad

when lifting up the vehicle.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
If the ganger is not properly installed, it may cause the

vibration that is very difficult to diagnose. Therefore, install
the hanger to the correct location so that the exhaust system cannot contact to the underbody and other
components.
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-37

System and principle
Oxidation catalytic technology for diesel engine is basically the same with it of gasoline engine used before development of 3 primary catalyst (2 primary catalyst), and
its effect and performance were already proved.
DOC (Diesel Oxidation Catalyst) reduces HO and CO contained exhaust gas over 80 %, and removes SOF (Soluble
Organic Fraction) over 50 ~ 80 %, but because its portion
in total PM is low, it reduces approx, 20 ~ 40 % of TPM
(Total Particulate Material).
Because of low reducing rate for PM of DOC, in order to
guarantee safety rate of PM regulation, this technology is
being used mainly. And it should keep over 80% of PM
reducing rate, and at present it plays a role as a transition
stage.
And also it reduces diesel odor and black smoke, platinum or palladium are being used as a catalyst.
On the other hand, it is a problem that it makes the reaction of oxidation, which SO2 produce SO3 and H2 SO4 by
reacting to oxygen in exhaust gas, if temperature of exhaust gas becomes over 300C, and this produced gas is
very harmful to human body. To prevent is, previously it is
requested that the sulfur content rate of fuel should be
below 0.05 %, and in the future it is being expected to
keep it below 0.01 %.
Catalytic converter structure

The Catalytic converter of monolith type consists of 2 walled
metal bodies which is made of Cordierite.
The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to
Ceramic Monolith. Washer coat operates first, and catalytic metal elements (Pt, Pd, Ph) operates to washer coat
next.
Monolith type is lighter than other types, easy to manufacture and quickly approaches to proper temperature.
Washer coat is used to make a contact surface with exhaust gas bigger by adhering closely to small holes of
inner layer.
If a lead compound or phosphorus adheres to the surface
and the temperature rises, its surface is decreased.
The total area of general monolith converter is about
45,000 ~ 500,000 ft 3. (10 times of a football field)
Generally Alumina (AL2O3) is used as a raw material and
its 7 phases of gamma, delta, theta have big areas and
high stability for the temperature, and nowadays gamma
Alumina is used usually.
Cover
Upper part of
converter
Insulation
Mat
Plate
Lower part of
converter
Monolith catalyst
Inlet gas
EXHAUST SYSTEM
DI ENG SM - 2004.9
Outlet gas
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-38
Catalytic converter and temperature
Catalytic converter has the normal function of purification at a
range of the temperature. Because it has a weak point of decreasing of the purification rate in the condition of continuous
high temperature, it should keep the temperature range of 400
to 500C for normal condition. HC purification rate becomes
better according to the increase of temperature in the normal
range of temperature. CO purification rate becomes the best
near the temperature of 450C, and NOx does so near the
temperature of 400 to 500C.
Purification of catalytic converter

Adhesion of soluble organic fraction (SOF) below 180C
Purification of soluble organic fraction (SOF) over 180C
Chemical reaction formula
SOF(HC) + O2 ............... O2 + H2O
2CO + O2 ...................... 2CO2
2C2H6 + 7O2 ................. 4CO2 + 6H2O
Aldehide
Aromatic HC
Oxygen adheres to catalytic material : below 180C

Catalytic Material
Catalytic Material
CHANGED BY
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AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-39
Catalytic material supplies each CO and HC with O2 for
their oxidation : above 180C
Catalytic Material
Catalytic Material
Catalytic material conversion process by DOC

PAH (Aromatic HC)
Catalyzer
Method for reduction of NOx

NOx is generated a great deal in case that combustion temperature and excess air factor are high. EGR valve can decrease NOx (30 to 35 % decrease) by making temperature of
combustion chamber fall by means of exhaust gas recirculation.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI04-40
Exhaust Pipe
1. Remove the upper bolts at turbo charger.
Notice
Use the universal type wrench.
2. Remove the lower bolts and gasket.
3. Remove the #1 hanger.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
EXHAUST SYSTEM
DI ENG SM - 2004.9
DI04-41
6. Remove the exhaust pipe.
EXHAUST SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI05-1
SECTION
00 DI05
LUBRICATION SYSTEM
Table of Contents
LUBRICATION SYSTEM ............................................. DI05-2
Lubrication system layout ....................................... DI05-3
Lubrication diagram ................................................ DI05-4
Specifications .......................................................... DI05-5
Engine oil change ................................................... DI05-9
Oil pump ................................................................ DI05-13
Oil spray nozzle ..................................................... DI05-15
Oil pan assembly .................................................. DI05-16
TROUBLE DIAGNOSIS ............................................. DI05-24
SPECIAL TOOLS AND EQUIPMENT ........................ DI05-25
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-2
LUBRICATION SYSTEM
Cylinder head cover
Oil dipstick
Oil separator
Oil filter
Oil pump
Oil pan
Oil cooler
Oil pressure switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-3
LUBRICATION SYSTEM LAYOUT

Main oil gallery: 16
Hole to cylinder head: 9
Main bearing hole: 7
Cylinder head
Chain and injection pump: 7

Return hole: 14
Chain nozzle: 1
HP pump bearing: 6
Cylinder block
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-4
LUBRICATION DIAGRAM
Chain lubrication
REF-Roller
Camshaft bearing
Vacuum pump
Oil tensioner
check valve
Return check valve
to cylinder head
Oil injection nozzle
Turbo charger
Connecting rod bearing Main bearing
Thrust bearing
Filter by-pass valve
Oil
filter
By-pass throttle
Contaminated oil
gallery
Oil pump
Clean oil gallery
Relief valve
Oil cooler
Fuel tank
1. Opening pressure of by-pass valve in oil filter: 3 0.4 bar

2. To prevent instant oil shortage after stopping the engine, the return check valve is installed in oil supply line of
cylinder head.
CHANGED BY
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AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-5
SPECIFICATIONS
Engine oil
Specification
Approved by MB Sheet 229.1 or 229.3

Viscosity: See MB Sheet 224.1
Capacity
6.8 ~ 8.3 liter
Service interval
Initial change: 5,000 km, Change every 10,000 km or

12 months (Frequently check the oil level and add if needed.
And, every 5,000 km or 6 months under severe conditions)
Engine oil filter
Same interval with engine oil
Oil relief valve opening pressure
5.8 0.3 bar
Severe condition:
- When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.
- When most trips are less than 6 km (Operating when outside temperatures remain below freezing and when most
trips are less than 16 km)
- When operating in dusty, sandy and salty areas
- In hilly or moutainous terrain
- When doing frequent trailer towing
Oil Pressure Switch

Operating temperature: -40 ~ 140C
Operating pressure: 0.3 ~ 0.55 bar
Permissible pressure: 10 bar
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-6
Oil Pump
Engine
Oil
Relief Valve Opening Pressure
D27DT
MB SHEET
229.1/3
5.8 0.3 bar
SAE 10W 40, 5W 40
Differences between D27DT and old model (D29ST)

- Enlarged pump capacity: Width of tooth (pump gear): 33 mm (D29ST: 30 mm)
- Increased number of teeth (sprocket): 26 (D29ST: 24)
Oil Cooler
Oil cooler mounting bolt: M6 x 16: 4
Tightening torque
10 Nm
Replace two oil cooler gaskets with new ones when the
oil cooler has been removed.
CHANGED BY
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AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-7
Blow-by Gas Reduction Device
Oil dipstick tube
PCV valve + oil

separator
to air duct
hose
Cylinder Head Cover

Blow-by gas inlet port
Baffle plate
U-type oil
drain pipe
Baffle plate assembly: The baffle plates in cylinder head cover separates oil and gas from blow-by gas, and controls the
blow-by gas speed to send only gas to separator.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-8
Oil Separator
PCV valve
Outlet port (gas only)
(connected to air duct hose)
Inlet port (oil + gas)

(connected to cylinder head cover
through blow-by hose)
Oil separator
Oil drain (oil only)

(connected to oil pan through oil dipstick tube)
The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover; then oil and gas
will be separated due to cyclone effect after entering the oil separator inlet port. Separated oil returns to oil pan via oil
drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that
opens/closes due to pressure differences between the intake side and crankcase.
Engine Oil Pressure Check

Check the oil level and quality before checking the oil pressure.
1. Drain the engine oil.
2. Disconnect the oil pressure switch connector and remove the switch.
3. Install the oil pressure gauge into the switch hole. Start the engine and let it run until the coolant temperature
reaches at normal operating temperature (80 ~ 90C).
4. Raise the engine speed by 2000 rpm and measure the engine oil pressure.
Specified oil pressure
2.5 ~ 3.0 kg/cm2(2000 RPM)
5. Install the switch and engage the connector.

Notice
Apply the Loctite onto the thread of the switch and

check for oil leaks.
Tightening torque
CHANGED BY
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AFFECTED VIN
120 ~ 160 kg/cm2

LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-9
ENGINE OIL CHANGE

Change interval: Initial change 5,000 km, Change every 10,000 km or 12 months
Frequently check and add if needed. Shorten the change interval under severe conditions.
* Severe condition:
- When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.
- When most trips are less than 6 km (Operating when outside temperatures remain below freezing and
when most trips are less than 16 km)
- When operating in dusty, sandy and salty areas
- In hilly or moutainous terrain
- When doing frequent trailer towing
Notice
Water separation from the fuel filter should be performed when changing the engine oil.
Engine Oil Changing Procedures

1. Park the vehicle on the level ground and warm up the
engine until it reaches normal operating temperature.
2. Stop the engine and wait around 5 minutes. Remove the
oil filler cap, oil filter and oil drain plug to drain the oil.
Notice
After driving, the engine oil temperature may be high

enough to burn you. Wait until the oil is cooled down.
3. Install new oil filter and tighten the drain plug with specified
tighten torque.
Oil drain plug
25 2.5 Nm
Notice
Over-tightening may cause oil leaks.

Replace the drain plug washer with new one.
4. Fill the engine oil through the oil filler opening.
Notice
The oil should not go above the upper mark on the dipstick. This would lead, for example, to increased oil
consumption, fouling of the spark plugs and excessive formation of carbon residue.
5. Close the oil filler cap and start the engine.
6. Stop the engine again and check the oil level. Add the engine oil if needed and check for the oil leaks.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-10
Engine oil filter change
1. For changing procedures, refer to the Lubrication System section in this manual.
Lubricate the engine oil gasket with engine oil before installation.
Tighten it with the specified tightening torque.
Oil filter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
25 2.5 Nm
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-11
Oil Filter and Cooler

Preceding Works:
- Draining of engine oil
- Removal of EGR vacuum modulator bracket
1. Remove the oil cooler hoses (supply and return lines).
2. Disconnect the ground cable from the oil pressure switch.
3. Remove the oil cooler and filter mounting bolt.

Installation Notice
Tightening torque
23 2.3 Nm
Pay attention to the length of bolts.
4. Remove the oil cooler and filter assembly from the cylinder
block.
Notice
The oil cooler and filter assembly cannot be replaced

separately.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI05-12
CHANGED BY
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AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-13
OIL PUMP
1. Oil pump
4. Guide pin
2. Plunger
5. Screw plug ...................................................... 50 Nm
Oil Pump - Removal and Installation

1. Remove the oil pan.
Tightening torque
Nm
M6 x 20 (24 EA)
10 1.0
M6 x 35 (2 EA)
10 1.0
M6 x 85 (2 EA)
10 1.0
M8 x 40 (4 EA)
25 2.5
2. Remove the oil pump.

3. Remove the screw plugs and the relief valve.
5. Start the engine and check for oil leaks.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-14
Oil Dipstick Guide Tube

1. Pull out the engine oil dipstick.
2. Remove the EGR valve pipe (No.3).
Installation Notice
Tightening torque
35 3.5 Nm
Replace the pipe with new one.
3. Unscrew the bolt and remove the oil dipstick guide tube.
Installation Notice
Tightening torque
10 Nm

Notice
After installation, check for oil leaks.
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AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-15
OIL SPRAY NOZZLE
1. Fitting sleeve
3. Combination bolt .............................................. 10 Nm
2. Oil spray nozzle
a. Oil duct
Disassembly
1. Remove the oil pan or crankshaft.
2. Unscrew the bolts and remove the nozzle.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI05-16
OIL PAN ASSEMBLY
1. Oil pump
44. Bolt ................................................................... 10 Nm
9. Oil pump cover
45. Washer
10. Bolt
46. Bolt
32. Drain plug washer
49. Oil pump roller chain
33. Drain plug .............. 25 2.5 Nm(replace the washer)
50. Oil pump chain lock link
35. Spring pin
51. Oil pump chain tensioner
36. Oil pump drive shaft
52. Oil pump chain spring
37. Oil pump driven shaft
53. Bush
38. Oil pump relief valve piston
39. Spring
57. Bolt
40. Oil pump relief valve pin
58. Dust cover
41. Oil pump relief valve plug
59. Cylindrical pin
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AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-17
BLANK
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI05-18
Removal and Installation of Oil Pan

Preceding works:
- Draining engine coolant
- Setting up the safety device for the sub frame and
removal of tires
- Removal of front propeller shaft
Procedures for Sub Frame Assembly

1. Placing the wheel chocks
The large portion of vehicle weight is applied to the
rear part of the vehicle when working on the 4-post
lift. Place the chocks under the rear wheels as
shown in the figure.
2. Installing the safety stands

To minimize the hazard, install two safety stands
under the sub frame before removing it. Pay particular attention that all the stands have same height.
16cm
3. Supporting points of auxiliary lift for sub frame

The auxiliary lift is used for removing and installing the sub frame. It should be located under the correct points in front
and rear sides of the sub frame. (The center point of gravity of sub frame is at the front axle mounting area.)
View from front side
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AFFECTED VIN
View from rear side
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-19
4. Installing the engine bracket
Remove the existing engine mounting brackets and install the special service tools (temporary engine bracket) on the correct locations (dotted circles
in the figure) before removing the sub frame.
Engine mounting
bracket
Special service tool

for engine mounting
A9912 008 2B
View from right side
LUBRICATION SYSTEM
DI ENG SM - 2004.9
View from left side
CHANGED BY
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AFFECTED VIN
DI05-20
Connections on the Sub Frame
1. Remove the high and low pressure pipes (A) of the steering
pump and lower arm shaft (B)
from the rear side of the sub
frame.
2. Remove the front brake caliper (D) and the wheel speed sensor (D).
(Attach the removed brake caliper and wheel speed sensor to the
vehicle after removing them.)
Suspension
Power steering pipe
3. Remove the high and low pressure pipes (A) of

the steering pump on the front side of sub
frame, and loosen the pipes.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4. Unscrew the bolts and nuts on the upper

end of the knuckle and lower end of the
shock absorber, and remove the knuckle
and shock absorber.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-21
2. Place each auxiliary lift under the front and rear side of the sub frame while taking care of the center point
of gravity. Mark on the mounting bolts of the sub frame, and remove the bolts (19mm x 6).
Installation Notice
Tightening torque
95 ~ 142 Nm
3. Remove the sub frame by lowering the auxiliary lifts.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-22
4. To prevent any damage, place the rubber blocks on the sub frame contact points in the 4-post lift before the sub
frame is lowered completely.
Rubber block installation points for front side of sub frame
Rubber block installation points for rear side of sub frame
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AFFECTED VIN
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-23
5. Install the sub frame in the reverse order of removal. Make sure that the sub frame is securely seated on the
mounting holes.
6. Unscrew the oil pan bolts (10 mm) and remove the oil pan.
LUBRICATION SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI05-24
TROUBLE DIAGNOSIS
Cause
Symptom
Excessive oil
consumption
Action
Loosened oil drain plug
Retighten
Loosen oil pan bolts
Retighten
Poor sealing at oil pan gasket
Replace
Loosened oil filter
Retighten
Loosened oil pressure switch
Retighten
Poor sealing at camshaft front oil seal
Replace
Poor sealing at crankshaft front oil seal
Replace
Poor sealing at crankshaft rear oil seal
Replace
Poor sealing at cylinder head cover gasket
Replace
Damaged cylinder head cover gasket
Replace
Oil intrusion into combustion chamber

Stuck piston ring
Remove carbon or replace ring
Worn piston or cylinder
Boring or replace
Worn piston ring or ring groove
Replace piston and piston ring
Improper position of ring cut-outs
Adjust
Worn or damaged valve mechanism
Replace
Oil leaks
Repair
Defective turbo charger
Check
Defective lubrication system
Low engine oil

pressure
CHANGED BY
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AFFECTED VIN
Improper viscosity
Replace with specified oil
Loosened oil pressure switch
Retighten
Low engine oil level
Add
Poor oil pump
Replace
Worn or damaged oil pump relief valve
Replace
Clogged oil filter or oil strainer
Replace or clean
Oil leaks
Repair
LUBRICATION SYSTEM
DI ENG SM - 2004.9
DI05-25

Application
103 589 02 09 00
Engine filter cap
LUBRICATION SYSTEM
DI ENG SM - 2004.9
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AFFECTED VIN
DI06-1
SECTION
00 DI06
COOLING SYSTEM
Table of Contents
COOLING SYSTEM .................................................... DI06-2
ENGINE COOLING SYSTEM ...................................... DI06-3
Specifications ........................................................ DI06-12
INSPECTION AND REPAIR ....................................... DI06-13
Inspection .............................................................. DI06-13
REMOVAL AND INSTALLATION ............................... DI06-15
PREHEATING SYSTEM ............................................ DI06-32
Overview ............................................................... DI06-33
Preheating relay ................................................... DI06-33
Preheating system diagram .................................. DI06-34
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI06-2
COOLING SYSTEM
Coolant reservoir
FFH
Coolant temperature
sensor
Radiator
Water pump
Cooling fan
FFH (Fuel Fired Heater): refer to FFH System in this manual.

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COOLING SYSTEM
DI ENG SM - 2004.9
DI06-3
ENGINE COOLING SYSTEM

Coolant
reservoir
Engine
Cylinder head
Thermostat
Radiator
Heater
Water pump
Cylinder block
Oil cooler
(Heater line)
<PTC Engine Coolant Flows>
Coolant
reservoir
Engine
Cylinder head
Heater
Radiator
Thermostat
Water pump
EGR cooler
(henceforth)
Cylinder block
Oil cooler
<FFH Engine Coolant Flows>
Cylinder block side

Block #5 Oil cooler Heater Heater water pump inlet pipe Water pump
Cylinder head side
Cylinder head Coolant outlet port (intake #1) Radiator Water pump
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-4
Function Description
Intake Manifold
Cylinder Head
Coolant Outlet Port
Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1)
: Improved shape and gasket material to prevent coolant from leaking
From cylinder head
From reservoir
From heater
In OM 600 engine, coolant inflows through the heater line rear section (cylinder #4 and #5) of cylinder head. However,
in D27DT engine, coolant inflows from cylinder block through oil cooler (refer to coolant flows layout in previous
page).
: It prevents cooling efficiency from decreasing due to coolant separation between cylinder #4 and #5.
In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected to
water pump with an additional pulley.
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COOLING SYSTEM
DI ENG SM - 2004.9
DI06-5
Radiator
This vehicle has a lightweight tube-and-fin aluminum radiator.
Be careful not to damage the radiator core when servicing.
Water pump
The belt-driven centrifugal water pump consists of an impeller,
a drive shaft, and a belt pulley. The impeller is supported by a
completely sealed bearing.
The water pump is serviced as an assembly and, therefore,
cannot be disassembled.
Coolant reservoir
Notice
Scalding hot coolant and steam could be blown out under

pressure, which could cause serious injury. Never remove
the coolant reservoir cap when the engine and radiator
are hot.
The coolant reservoir is a transparent plastic reservoir, similar
to the windshield washer reservoir. The coolant reservoir is
connected to the radiator by a hose and to the engine cooling
system by another hose. As the vehicle is driven, the engine
coolant heats and expands. The portion of the engine coolant
displaced by this expansion flows from the radiator and the
engine into the coolant reservoir. The air trapped in the radiator and the engine is degassed into the coolant reservoir.
When the engine stops, the engine coolant cools and
contracts. The displaced engine coolant is then drawn back
into the radiator and the engine. This keeps the radiator filled
with the coolant to the desired level at all times and increases
the cooling efficiency. Maintain the coolant level between the
MIN and MAX marks on the coolant reservoir when the system is cold.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-6
Thermostat
A wax pellet-type thermostat controls the flow of the engine
coolant through the engine cooling system. The thermostat is
mounted in the water pump housing. The thermostat stops
the flow of the engine coolant from the engine to the radiator
to provide faster warm-up, and to regulate the coolant
temperature. The thermostat remains closed while the engine
coolant is cold, preventing circulation of the engine coolant
through the radiator. At this point, the engine coolant is allowed to circulate only throughout the heater core to warm it
quickly and evenly. As the engine warms, the thermostat
opens. This allows the engine coolant to flow through the radiator where the heat is dissipated. This opening and closing
of the thermostat permits enough engine coolant to enter the
radiator to keep the engine within proper engine temperature
operating limits. The wax pellet in the thermostat is hermetically sealed in a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine
coolant temperature increases. When the engine coolant
reaches a specified temperature, the wax pellet element in
the thermostat expands and exerts pressure against the metal
case, forcing the valve open. This allows the engine coolant to
flow through the engine cooling system and cool the engine.
As the wax pellet cools, the contraction allows a spring to
close the valve.
The thermostat begins to open at 85C and is fully open at
100C. The thermostat closes at 85C.
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AFFECTED VIN
Thermostat
Operating
Temperature (C)
Opening Value (mm)
Begins to open
85C
0.1 mm
Fully open
100C
8 mm
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-7
When closed (up to 85C)
When partially opened (85C ~ 100C)
X. from cylinder head

Y. to crankcase
Z. from radiator
When fully opened (above 100C)

If the cooling system is fully filled with, the coolant is automatically bled through ball valve (arrow) in thermostat.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-8
Viscous fan clutch
The cooling fans are mounted behind the radiator in the

engine compartment. The electric cooling fans increase
the flow of air across the radiator fins and across the condenser on air conditioner. The fan is 320 mm in diameter
with five blades to aid the airflow through the radiator and
the condenser. An electric motor attached to the radiator
support drives the fan.
1. A/C Off or Non-AC Model
1. Clutch housing
9. Pin
2. Drive disc
10. Bi-metal
3. Flange
11. Bracket cover
4. Seal ring
12. Separator disc
5. Needle bearing
13. Supply port
6. Cooling fan
14. Lever valve
7. Oil scraper
15. Oil chamber
8. Spring
16. Operating chamber
The cooling speed increases approx. 1,000 rpm with wind

noise when the engine speed is 4,000 to 4,500 rpm and
the coolant temperature is 90 to 95C.
Notice
The cooling fan operates at low speed when the

coolant temperature reaches 95C and at high
speed when the coolant temperature reaches
100C.
The cooling fan is turned from high speed to low
speed at 97C and turns off at 90C.
2. A/C On
The ECU will turn the cooling fan on at high speed
when the A/C system is on.
Engine coolant temperature sensor

The Engine Coolant Temperature (ECT) sensor uses a temperature to control the signal voltage to the Engine Control
Unit (ECU).
Keep hands, tools, and clothing away from the engine

cooling fans to help prevent personal injury. This fan
is electric and can turn on even when the engine is
not running.
Notice
If a fan blade is bent or damaged in any way, no attempt

should be made to repair or reuse the damaged part.
A bent or damaged fan assembly should always be
replaced with a new one to prevent possible injury.
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AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-9
Coolant Level Check

Notice
Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury. Never
remove the coolant reservoir cap when the engine and radiator are hot.
Take precautions to prevent antifreeze coming in contact with the skin, eyes or vehicle body. If contact
happens, rinse affected areas immediately with plenty of water.
1. Place the vehicle on a level ground and check the coolant level through the coolant reservoir.
2. Add if needed. Change the coolant if necessary.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-10
Coolant Temperature Sensor
Temp.
Resistance
<Coolant Temperature Sensor>
<Output Characteristics of Coolant Temperature Sensor>
Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects lowering
signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if engine temperature is too low, the fuel injected as foggy state forms big compounds causing incomplete combustion. So the sensor detects
coolant temperature and changes coolant temperature changes into voltage then sends to ECU to increase the fuel volume
during cold start for better starting. And detects engine overheating for fuel volume reduction to protect the engine.
ECU functions as below with coolant temperature sensor signals.
When engine is cold, controls fuel volume to correct idle speed
When engine is overheated, controls electrical fan and A/C compressor to protect the engine
Sends information for emission control
Temperature
NTC 1 Resistance ( )
NTC 2 Resistance ( )
20
2,550
6,062
50
826
1,800
80
321
638
120
123
200
Signal
Auto amp
Ground
<Coolant Temperature Sensor Circuit>

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COOLING SYSTEM
DI ENG SM - 2004.9
DI06-11
Trouble Diagnosis
Symptom
Low coolant
level
Excessively
high coolant
temperature
Cause
Action
Leaks in radiator
Replace radiator
Leaks in coolant reservoir
Replace coolant reservoir
Leaks in heater core
Replace heater
Leaks in hose connection
Reconnect hose or replace clamp
Damaged coolant hose
Replace hose
Leaks in water pump gasket
Replace gasket
Leaks in water pump internal seal
Replace water pump
Leaks in coolant inlet cap
Replace water inlet cap gasket
Leaks in thermostat housing
Replace thermostat sealing
Improper tightening torque of cylinder head
Retighten
Damaged cylinder head gasket
Replace cylinder head gasket
Coolant leaks (too low coolant level)
Add coolant
Improper coolant mixture ratio
Check coolant concentration
Kinked coolant hose
Repair or replace hose
Defective thermostat
Replace thermostat
Defective water pump
Replace water pump
Defective radiator
Replace radiator
Defective coolant reservoir and cap
Replace coolant reservoir or cap
Cracks on cylinder head or cylinder block
Replace cylinder head or cylinder block
Clogged coolant passages in cylinder head or cylinder block Clean coolant passages
Excessively
low coolant
temperature
COOLING SYSTEM
DI ENG SM - 2004.9
Clogged radiator core
Clean radiator core
Improper operation of cooling fan
Replace cooling fan or repair related circuit
Faulty temperature sensor or defective harness
Replace sensor or repair related circuit
Stuck thermostat (with open)
Replace thermostat
Improper operation of cooling fan
Replace cooling fan or repair related circuit
Faulty temperature sensor or defective harness
Replace sensor or repair related circuit
CHANGED BY
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AFFECTED VIN
DI06-12
SPECIFICATIONS
Description
Cooling system
Type
Coolant
Capacity
Thermostat
Type
Water pump
Water cooling forced circulation
Wax pellet type
Initial opening temperature
DI
85
Fully opening temperature
DI
100
Fully closing temperature
DI
83
Stroke
DI
mm
min. 8
Electric
Blades
Diameter
Coolant reservoir
Specification
11.3
Type
Cooling fan
Unit
5
mm
320 (2)
Low speed ON temp
91
Low speed OFF temp
88
High speed ON temp
95
High speed OFF temp
92
High speed ON temp. (By A/C pressure)
psi
270
pressure valve opening pressure
Kg/cm2
1.2 ~ 1.5
Vacuum valve opening pressure
Kg/cm2
0.1
Turbo centrifugal
mm
72.3
Type
Impeller diameter
Impeller blades
Radiator
10
-
Down-flow
Core width
mm
701
Core height
mm
372
Core thickness
mm
18
Kcal/h
45,000
Type
Minimum radiation capability

Resistance (at 20C)
3.33 ~ 3.78
Resistance (at 80C)
0.32 ~ 0.35
Anti-freeze agent
Type
ALUTEC-P78
Mixture ratio (water and anti-freeze)
50 : 50
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AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-13
INSPECTION AND REPAIR

INSPECTION
Cooling System
1. Release the pressure from coolant reservoir by loosening
one notch of coolant reservoir cap, and then remove the
cap.
Notice
Scalding hot coolant and steam could be blown out

under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
before the temperature goes down below 90C.
2. Add the coolant up to upper mark (arrow) on the reservoir.
3. Install the tester to the coolant reservoir and apply the
pressure of 1.4 bar.
4. Check the coolant hoses, pipes and connections for leaks
after the pointer of the tester drops. Replace or retighten
as required.
Thermostat
Immerse the thermostat into the water. Heat the water and
check the valve opening temperature.
Valve opening temperature
COOLING SYSTEM
DI ENG SM - 2004.9
Temperature gauge
DI Engine: 85 2C
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-14
Coolant Temperature Gauge Unit

1. Immerse the senor unit into the water. Heat the water
and check the resistance.
2. If the measured resistance is out of specified value,

replace the gauge unit.
3. Measure the resistance between terminal A and gauge
unit housing, and terminal B and gauge unit housing.
Terminal A
Terminal B
Terminal A
(for coolant temp.)
Terminal B
(for glow plug)
0.4 / 79C
23.8 / 115C
24.8 / -20C
3.25 / 20C
Thermostat
1. Immerse the thermostat into the oil. Heat the oil until it
reaches the specified temperature and check if the
coolant temperature switch is turned OFF.
Coolant temperature at
point A
113 3C
Coolant temperature at
point B
116C
Notice
Use only engine oil for this inspection. Stir the oil
during heating it. Never heat the oil over required
temperature.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-15
REMOVAL AND INSTALLATION

Water Pump - Assembly
Preceding Works:
- Draining of coolant
- Removal of V-belt
- Removal of shroud
- Removal of cooling fan
1. Thermostat housing
4. Belt pulley
2. Gasket ........................................................... Replace
5. Bolt ................................................................... 10 Nm
3. Bolt ................................................................... 10 Nm
6. Water pump
1. Remove the V-belt while pressing down the auto tensioner

adjusting bolt.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-16
2. Unscrew the bolts and remove the EGR pipe and bracket.
Installation Notice
Tightening torque
23 2.3 Nm
3. Unscrew the bolts and remove the belt pulley while

holding the belt pulley with a special tool.
Installation Notice
Tightening torque
10 Nm
4. Remove the oil dipstick tube.

Notice
Replace the O-ring in oil dipstick with new one.

Plug the oil dipstick hole with a cap not to get the
foreign materials into the engine.
5. Unscrew the bolts and remove the water pump assembly.

Installation Notice
Tightening torque
10 Nm
Notice
Remove the gasket residues from the sealing surface

and replace the gasket with new one.

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-17
Thermostat
Preceding Works:
-
Draining of coolant
Removal of V-belt
Removal of cooling fan
Removal of intake duct (air cleaner to turbo charger)
1. Gasket ...................................................... Replace
5. Thermostat
2. Water pump housing
6. Seal
3. Connector
7. Coolant hose
4. Bolt ............................................................. 10 Nm
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-18
1. Unscrew the bolts and remove the thermostat housing.
Installation Notice
Tightening torque
10 1.0 Nm
2. Remove the thermostat.

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-19
Water Pump Housing

Preceding Works:
- Removal of water pump assembly
- Removal of thermostat assembly
1. Remove the heater hose.
2. Unscrew the bolts and remove the alternator.

Installation Notice
Tightening torque
46 4.6 Nm
3. Unscrew the bolts and remove the alternator bracket.

Installation Notice
Tightening torque
25 2.5 Nm
4. Unscrew the bolts and remove the water pump housing.

Installation Notice
Tightening torque
10 1.0 Nm
Notice
Be careful not to damage the O-ring in coolant outlet
pipe (cylinder head side).
Remove the gasket residues from the sealing
surface and replace the gasket with new one.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-20
Radiator
Components of Radiator Module
Related Components (Assembly): Intercooler, Electric Fans, Condenser, Radiator
Preceding Work:
- Disconnection of negative battery cable
- Removal of front bumper assembly
- Discharge of refrigerant
- Draining of engine coolant
Removal Procedure
Intercooler
Radiator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Electric Fans
Condenser
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-21
Tightening Torques in Intake System
The clamp in the intake system related with intercooler may be moved out of its location due to the pressure from the
turbo charger when the proper tightening torque is not achieved. Always tighten the clamps to the specified value with a
torque wrench or ratchet wrench.
Tightening torque
COOLING SYSTEM
DI ENG SM - 2004.9
6 ~ 7 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-22
Intercooler Assembly
1. Disconnect all wiring harnesses and related connectors from the front side of radiator assembly.
AQS sensor

[for FFH]
Ambient temperature
sensor
Connector
[for air conditioner]
Receiver drier
Electric fans
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-23
2. Remove the front end center member.
3. Remove the hood latch cable and remove the radiator support upper member.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-24
4. Remove the intercooler inlet hose.
Tightening torque
5. Remove the intercooler outlet hose.

6 ~ 7 Nm
Tightening torque
6 ~ 7 Nm
6. Unscrew the bolts and remove the intercooler assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-25
Electric Fans
1. Disconnect the electric fan connectors.
2. Unscrew the bolts at both sides and remove the electric fan assemblies.
Appearance
Front view
COOLING SYSTEM
DI ENG SM - 2004.9
Rear view
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-26
Condenser Assembly
1. Disconnect the receiver drier connector.
2. Remove the air conditioner inlet pipe bolt.
Appearance
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-27
Fan Shroud
1. Remove the coolant return pipe.

2. Remove the mounting bolt (
engine.
3. Remove the bolt (

side.
COOLING SYSTEM
DI ENG SM - 2004.9
) from the front side of the
) at bottom of the fan shroud and remove the fan shroud by pulling up the clip at the opposite
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-28
Fan Clutch
Unscrew the bolts with the fan clutch pulley locked by a special tool and remove the fan clutch.
Appearance
Front view
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear view
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-29
Fan Belt
Remove the fan belt with the tensioning shock absorber depressed (counter-clockwise direction).
Fan Belt Arrangement
Cooling fan pulley
Idle pulley
Auto temsioner pulley
Water pump pulley
Power steering pump pulley
Alternator pulley
Air conditioner
comperessor pulley
TVD (Torsional
Vibration Damper)
COOLING SYSTEM
DI ENG SM - 2004.9
Auto tensioner
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-30
Coolant Reservoir
2. Remove the hoses.
3. Unscrew the bolts and remove the coolant reservoir.

Installation Notice
Tightening torque
7 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-31
Draining and Adding of Coolant

1. Release the pressure from coolant reservoir by loosening
one notch of coolant reservoir cap, and then remove the
cap.
Notice
Scalding hot coolant and steam could be blown out

under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
before the temperature goes down below 90C.
2. Loosen the drain plug in bottom of radiator and drain the
coolant.
Notice
Collect the drained coolant with a proper container.
3. Remove the drain plug and seal in the cylinder block and
drain the coolant.
4. Replace the seal with new one and install the drain plug.
Installation Notice
Tightening torque
30 Nm
5. Install the drain plug in bottom of radiator.

6. Add the coolant through the coolant reservoir.
Notice
Keep the coolant mixture ratio of 50:50 (water : antifreezer).

Add the coolant until the water flows out through
the overflow hose.
7. Warm up the engine until the thermostat begins to open
and check if the coolant level is at FULL mark on the
reservoir. Add if necessary.
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-32
PREHEATING SYSTEM
ECU
Glow plug
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Glow indicator (meter cluster)
Preheating relay
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-33
OVERVIEW
Glow plug is installed on the cylinder head (combustion chamber) in the D27DT preheating control unit system. Cold
starting performance has improved and exhaust gas during cold starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/after heating and
glow plug diagnosis function, the fault contents will be delivered to ECU.
Engine preheating/after heating functions
Preheating relay activation by ECU controls
- Senses engine temperature and controls the preheating/after heating time
- Glow indicator
K-LINE for information exchanges between preheating unit and ECU
- Transmits preheating unit self-diagnosis results to ECU
- Transmits glow plug diagnosis results and operating status to ECU
PREHEATING RELAY
Structure
K-LINE #1
(ECU 34)
IG1
Power terminal
Glow plug
control signal
(ECU 113)
Ground terminal
B+main wire
(12V)
Glow plug
terminal
Y220_06069
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-33
OVERVIEW
- Glow indicator
PREHEATING RELAY
Structure
K-LINE #1
(ECU 34)
IG1
Power terminal
Glow plug
control signal
(ECU 113)
Ground terminal
B+main wire
(12V)
Glow plug
terminal
Y220_06069
COOLING SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI06-34
PREHEATING SYSTEM DIAGRAM
Coolant
temperature
sensor
Specifications
Description
Specification
Rated voltage
DC 12 V
Operating voltage range
DC 8 ~ 15 V
Operating range
- 40 ~ + 100C
Relay operating voltage
Over 6.5 V
Relay releasing voltage
Over 1.5 V
Relay coil resistance
11.3
Voltage drop
Below 150 mV at each glow plug (at 16A of current)
Parasitic current
MAX 1mA
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EFFECTIVE DATE
AFFECTED VIN
COOLING SYSTEM
DI ENG SM - 2004.9
DI06-35
Function
Preheating system controls and checks following functions and operating conditions.
Pre-Heating
The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from
the battery and there are normal communications with ECU within 2 seconds. The surface of glow plug will be
heated up to 850C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
Preheating time is controlled by ECU.
After-heating
When the engine is started, after-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
After-heating time is controlled by ECU.
Checking glow plugs
Check each glow plug for short in circuit
Check each glow plug for open in circuit due to overvoltage
Check glow plug for short to ground
Forceful relay shut-down
When glow plug is shorted to ground
K-Line communication
ECU sends the results to preheating time control relay through K-Line to start communication.
Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
Glow plug makes communication only as response to demand.
When power is supplied, ECU starts self-diagnosis within 2 seconds.
Under the following conditions, communication error occurs.
- When there is no response from glow plug module within 2 seconds
- When an error is detected in checksum
- Less byte is received
Error code of P1720 - Pre heating control communication fail will be reported.
Operating time
Preheating
Afterheating
Glow
Indicator
Coolant Temp.
-35 C
-25 C
-20 C
-10 C
0 C
10 C
20 C
Operating Time
31 sec
22 sec
19 sec
17 sec
14 sec
0 sec
0 sec
Operating
Conditions
IG: ON
Coolant Temp.
-30 C
-20 C
-10 C
0 C
10 C
20 C
35 C
Operating Time
115 sec
80 sec
30 sec
19 sec
11 sec
11 sec
0 sec
B+ : below 15.2V
After operating time elapsed

Release
Torque : 190/170 Nm
Conditions
Speed: 2100/2050 rpm
After engine starting

Operating
Conditions
Coolant Temp.
-30 C
-25 C
-20 C
-10 C
0 C
10 C
20 C
Operating Time
18 sec
16 sec
10 sec
5 sec
2 sec
0 sec
0 sec
Operating
Conditions
IG: ON
COOLING SYSTEM
DI ENG SM - 2004.9
After operating time elapsed

Release
Conditions IG: OFF When engine cranking
Release
When engine cranking
Conditions
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AFFECTED VIN
DI07-1
SECTION
00 DI07
FUEL SYSTEM
Table of Contents
CAUTIONS FOR DI ENGINE ....................................... DI07-2
FUEL SYSTEM ............................................................ DI07-6
Fuel injection system .............................................. DI07-6
Fuel transfer line ................................................... DI07-12
Inlet metering valve (IMV) ..................................... DI07-19
High fuel pressure line .......................................... DI07-22
Injector .................................................................. DI07-35
REMOVAL AND INSTALLATION OF FUEL TANK .... DI07-49
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-2
CAUTIONS FOR DI ENGINE

This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine,
warning lights, symptoms when engine malfunctioning, causes and actions.
DI Engine
Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically, delivers high
power and reduces less emission.
System Safety Mode

When a severe failure has been occurred in a vehicle, the
system safety mode is activated to protect the system. It
reduces the driving force, restricts the engine speed (rpm)
and stops engine operation. Refer to Diagnosis section
in this manual.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Water Separator Warning Light

When the water level inside water separator in fuel filter exceeds a certain level
(approx. 39 cc), this warning light
comes on and buzzer sounds.
Also, the driving force of the vehicle
decreases (torque reduction). If these
conditions occur, immediately drain
the water from fuel filter.
For the draining procedures, please refer to Draining the water from fuel filter in this section.
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-3
Priming Pump
The priming pump installed in fuel pump is the device to fill the fuel into the fuel filter. When the vehicle is under the
conditions as below, press the priming pump until it becomes rigid before starting the engine.
WARNING
Never reverse filter or use it in other place (clean side)
Conditions for using Priming Pump

1. After run out of fuel
2. After draining the water from fuel separator
3. After replacing filter or any intervention on system
Fuel Filter and Water Separator
1. Fuel filter
2. Water drain plug
3. Priming pump
(to be drained every 15,000km max.)
4. Water separator
Draining could be done at same time than oil

change
Notice
When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes
rigid before starting the engine.
The water drain from fuel filter should be performed whenever changing the engine oil.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-4
Draining the Water From Fuel Filter

for EU Area
1. Place the water container under the fuel filter.
2. Turn the drain plug (2) to A direction to drain the water.

3. Press priming pump until all water is drained, then turn
the drain plug to B direction to tighten it.
Notice
Be careful not to be injured by surrounding

equipment during the working procedures.
4. Press the priming pump until it becomes rigid.

5. Start the engine and check the conditions.
6. Clear the fault code of ECU with scan 100.
WARNING
If the priming pump is not properly operated, air may

get into the fuel line. It may cause starting problem
or fuel system problem. Make sure to perform the
job in step 4.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-5
Draining the Water From Fuel Filter for General Area
1. Place the water container under the fuel filter & water
separator.
2. Disconnect the connector under the drain plug of the water
separator.
3. Turn both drain plugs to A direction to drain the water.
4. Wait until a certain amount of fuel gets out from the port,
then turn the both drain plugs to B direction to tighten it.
Notice
Be careful not to be injured by surrounding

equipment during the working procedures.
4. Engage the connector under the drain plug and press
the priming pump until it becomes rigid.
1. Fuel filter
5. Start the engine and check the conditions.
3. Water separator
6. Clear the fault code of ECU with SCAN-100.
4. Drain plug
2. Priming pump
5. Connector
WARNING
If the priming pump is not properly operated, air may

get into the fuel line. It may cause starting problem
or fuel system problem. Make sure to perform the
job in step 4.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-6
FUEL SYSTEM
FUEL INJECTION SYSTEM
Electronic Control of Fuel System
High pressure pump
Common rail
IMV valve
Low and high
pressure pump
Fuel temperature
sensor
Injection
pipe
Water separator
Fuel filter
Priming
pump
Water detection
sensor
Injectors
Sensors
HFM sensor
Cam position sensor
Fuel tank
ECU

Knock sensor, etc.
System composition
- High pressure fuel pump - Fuel rail
- Fuel injector
- Fuel pressure sensor
- Electronic control unit (ECU) - Other sensors and actuators
Supply line
Return line
ECU connecting line
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects drivers pedal position (drivers demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and
sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume
changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from
coolant temperature sensor and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as
compensation signal to respond to injection starting, pilot injection set values, various operations and variables.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-7
Composition of Fuel System

Components in fuel system are designed to generate and distribute high pressure, and they are controlled electronically
by engine ECU. Accordingly, fuel system is completely different from injection pump type fuel supply system on the
conventional Diesel engine. The fuel injection system in common rail engine is composed of transfer pressure section
that transfers fuel in low pressure, high pressure section that transfers fuel in high pressure and ECU control section.
High pressure pipe
Common rail
Injector
Priming pump
Fuel pump
(High pressure pump, transfer pump)
Fuel filter
<Fuel line system>
Fuel route
Fuel tank
Priming pump
Fuel filter
Transfer
pump
Transfer pressure line
Injector
Common rail
High pressure
pump
Fuel pressure
regulation valve
High pressure line

FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-8
Hydraulic cycle in Fuel Line (Transfer and High Pressure Line)
Transfer pressure regulation
Pressure limiter
(High pressure)
Transfer pump
High pressure pump
Return
valve
Inlet
valve
below 2 bar
below - 0.3 bar
Venturi
Common rail
Up to
1050 bar
* At IMV full open
- 0.6 ~ 0.1 bar
0.05 ~ 0.1 bar

Fuel
filter
Injector
Priming pump
High pressure supply line

Transfer pressure supply line
Fuel tank
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Return line
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-9
Components of Low Pressure Transfer Line

Low pressure stage is to supply sufficient fuel to high pressure section and components are as below.
Fuel tank (including strainer)
Hand priming pump
Fuel filter
Transfer pump
Other low pressure fuel hoses
Fuel tank
Fuel tank is made of anti-corrosion material and its allowable
pressure is 2 times of operating pressure (more than 0.3 bar).
It has protective cap and safety valve to prevent excessive
pressure building. Also, it has structure to prevent fuel from
leaking in shocks, slopes and corners and to supply fuel
smoothly.
Priming pump
If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or damage to each component. Therefore, the hand priming pump is
installed to bleed air from transfer line.
When the vehicle is under the conditions as below, press the
priming pump until it becomes rigid before starting the engine.
- After run out of fuel
- After draining the water from fuel filter
- After replacing the fuel filter
Press the priming pump until it becomes rigid before starting
the engine.
Fuel filter
It requires more purified fuel supply than conventional diesel
engine. If there are foreign materials in the fuel, fuel system
including pump components, delivery valve and injector nozzles
may be damaged.
Fuel filter purifies fuel before it reaches to high pressure pump
to help proper operations in high pressure pump. And more, it
separates water from fuel to prevent water from getting into
FIE system (high pressure line).
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-10
Transfer pump
The transfer pump is included in the housing of the high pressure pump. The transfer pump is the volumetric blade type
pump. To deliver the continuously required fuel volume, the
pump transfers fuel from the fuel tank to high pressure pump.
Components of High Pressure Transfer Line

In the high pressure section, sufficient fuel pressure that injectors requires will be generated and stored. The components are as below:
High pressure pump
Rail pressure sensor
Pressure limit valve
Common rail
High pressure pipe
Injector
Fuel pressure regulating valve (IMV)
High pressure pump (including IMV and limit valve)

This is plunger pump that generates high pressure; and driven
by crankshaft with timing chain. The high pressure pump increases system pressure of fuel to approx. 1,600 bar and this
compressed fuel is transferred to high pressure accumulator
(common rail) in tube through high pressure line.
Common rail (including pressure sensor)

It stores fuel transferred from high pressure pump and also
stores actual high pressure of fuel. Even though the injectors
inject fuel from the rail, the fuel pressure in the rail is maintained to a specific value. It is because the effect of accumulator is increased by unique elasticity of fuel. Fuel pressure is
measured by rail pressure sensor. And the inlet metering valve
(IMV) included in high pressure pump housing keeps pressure to a desired level.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-11
High pressure pipe (fuel pipe)
Fuel line transfers high pressure fuel. Accordingly, it is made
of steel to endure intermittent high frequency pressure changes
that occur under maximum system pressure and injection
stops. Injection lines between rail and injectors are all in the
same length; it means the lengths between the rail and each
injector are the same and the differences in length are compensated by each bending.
No.1 and 3 cylinder
No. 5 cylinder
No.2 and 4 cylinder
Injectors
The fuel injection device is composed of electrical solenoid
valve, needle and nozzle and controlled by engine ECU. The
injector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine. When
injector nozzle is open, remaining fuel after injection returns
to fuel tank through return line.
Fuel Filter Replacement

* Fuel filter change interval: every 30,000 km
* Water separation interval: every 15,000 km max. (same
with engine oil change interval)
* Never reuse the removed fuel filter
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-12
FUEL TRANSFER LINE

Fuel Filter
Function
Foreign materials in fuel can damage the pump components, transfer valve and injectors. Therefore, the high pressure
direct injection engine must use fuel filter. Otherwise, the operation performance will drop dramatically. And, diesel fuel
may contain water due to condensation by temperature changes and this condensation water can damage the system
by corroding the injection system. Thus, the common rail engine should have function that can drain water periodically.
from HP pump
to fuel tank
to HP pump
from fuel tank
Water Sensor
Capacity: 120 cm
Fuel filter
3
Warning light ON level: 39 cm 3
Filter volume: 500 25 cm 3

Filtering efficiency
Particles larger than 3mm > 98 %
Particles larger than 5mm > 99.8 %
Particles larger than 15mm > 100 %
Drain plug
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-13
Change Interval: 30,000 km
Water separation and storage function
Function: It separates the condensation water from diesel fuel to prevent the water from getting into FIE system, and
results in protection of FIE system. (manual drain)
Water storage capacity: 120 cc
Water sensor: light if over 39 cc
Water drain interval: When changing engine oil or every 20,000 km
Water sensor
It is integrated in the filter and sends signal to ECU when water level reaches at a specified value (over 39 cc) in the filter
to let the driver drain the water.
Fuel De-Waxing Improving starting performance in cold weather

Due to characteristics of diesel fuel, some of fuel components solidify during cold winter under below a specific temperature (-15C). When those symptoms happen, engine may stall; however, some of the fuel (temperature rises due to high
compression) in the HP pump in D27DT engine return to the filter to warm up fuel when temperature is below 50C by
improving cold start performance during cold winter.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-14

1. Disconnect the fuel supply and return hoses.
Notice
Plug the openings of hoses and fuel filter with

sealing caps.
Ensure that the hoses are connected to correct
positions.
2. Loosen the bracket bolts and disconnect the hose from

the drain plug.
3. Remove the fuel filter.
5. Press the priming pump until it becomes rigid to deliver
the fuel to the transfer line of HP pump.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-15
Water Separator (General Area Only)

Function
The water separator is used in the fuel supplying system in order to reduce the water content in the fuel provided to the
FIE system.
It gives additional water volume storage. A water sensor is fitted to the water separator in order to:
- Warn the driver that the water separator has to be drained
- In case of coupling the water separator to a filter, it reduces the amount of water seen by the filter.
The water sensor is connected to the ECU. The sensor is fitted on the bottom part of the water separator where water
separated from the fuel is stored.
When using the water separator coupled to fuel filter, 80 % of the volume of water separated is stopped in the water
separator.
Fuel outlet tube

Fuel inlet tube
Sedimentor cover
Sedimentor bowl
Cylindrical mesh
Schematic representation of the inner design

Water sensor
Capacity: 300 cm3
Warning light ON level: 39 cm 3
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-16
Priming Pump
If fuel runs out during driving or air gets into fuel line after fuel
filter replacement, it may cause poor engine starting or damage to each component. Therefore, the hand priming pump is
installed to fill filter.
to fuel filter
When the vehicle is under the conditions as below, press the

priming pump until it becomes rigid before starting the engine.
Conditions for using Priming Pump
from fuel tank
- After run out of fuel

- After draining the water from fuel filter
- After replacing the fuel filter
Notice
When the fuel filter is replaced, the fuel in the fuel tank should be transferred to the filter by using priming
pump. So never transfer the fuel in the fuel tank to the filter by driving HP pump with cranking the engine.
Relations Between Pressure and Temperature In Fuel Transfer Line

Pump inlet pressure
Pump
High pressure common rail

Fuel transfer
line
Ventury
Pump outlet pressure
Injector
Injector No.1 return pressure
Injector No.5 return pressure
The fuel transfer line is the line between fuel tank and HP pump inlet port. The pressure on this line affects the
lifetime of fuel filter.
Temperature of fuel transfer line
- HP pump inlet temperature is less than 80C.
- The temperature of fuel pump inlet is up to 80C.
And, diesel fuel has lubrication effects due to its viscosity. Thus, the fuel is also used for pump lubrication.
However, this lubrication performance drops as the temperature rises. Accordingly, when the fuel temperature is
over 50C, 100% of fuel is returned to fuel tank to cool down the temperature and then increase the lubrication
effects of fuel and prevent heat damage on each section of high fuel pressure line.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-17
Transfer Pump
Description
The transfer pump is the device to provide sufficient fuel to high fuel pressure line and is mechanical type feed pump that
is driven by timing chain linked to crankshaft. This mechanical type feed pump is subject to air inflow, therefore, a hand
priming pump is installed to fill fuel in Low fuel pressure(LP) circuit.
The transfer pump is included in the housing of the HP pump. The transfer pump is the volumetric blade type pump and
consists of the following components:
A rotor turned by the shaft of the HP pump. The connection is provided by splines.
An eccentric liner fixed to the housing of the HP pump by 6 Torx bolts. The liner is positioned by two off-set pins in
order to prevent any assembly errors.
Four blades set at 90. Each blade is held against the liner by a coil spring.
The inlet and outlet orifice.
Transfer pump
HP pump
<Sectional view of fuel pump>
<Sectional view of transfer pump>
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-18
Principle of operation
Housing
Rotor
OUT
Blade
Chamber
Consider the chamber between the rotor, the liner and two successive blades (refer to above figure).
When the chamber is in position 1, the volume of the chamber is minimal. The changes in volume according to the
angle of rotation of the rotor are small.
The rotor makes a quarter turn clockwise. The previous chamber is now in position 2.
The inlet orifice is uncovered. The volume contained in the chamber quickly rises. The pressure inside the chamber
drops sharply. Fuel is drawn into the chamber.
The rotor continues to rotate. It is now in position 3. The inlet and outlet orifices are now sealed off. The volume area
controlled by the rotor, the liner and the two blades is at the maximum. The changes in volume according to the
angle of rotation of the rotor are small.
The rotor continues to rotate. It is finally in position 4. The outlet orifice is uncovered. The volume area controlled by
the rotor, the liner and the blades decreases quickly. The pressure inside the chamber rises sharply. The fuel is
expelled under pressure. The depression caused by the transfer pumps rotation is sufficient to draw in diesel fuel
through the filter. The transfer pump is driven by the shaft of the HP pump, transfer pressure thus rises with engine
speed. A regulating valve allows the transfer pressure to be maintained at a practically constant level (about 6 bar)
throughout the whole range of engine operations by returning some of the fuel to the pump inlet.
Fuel
pressure
(bar)
Fuel pump speed (rpm)
Characteristics of the transfer pump

Regulating pressure
6 bar
Volume controlled
5.6 cm3/revolution
Flow
90 /h at 300 rpm pump

650 /h at 2,500 rpm pump
Intake capacity
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
65 mbar at 100 rpm pump

FUEL SYSTEM
DI ENG SM - 2004.9
DI07-19
INLET METERING VALVE (IMV)

Overview
The LP actuator, also called the inlet metering valve, is used
to control the rail pressure by regulating the amount of fuel
which is sent to the pumping element of the HP pump.
This actuator has two purposes:
1. Firstly, it allows the efficiency of the injection system to

be improved, since the HP pump only compresses the
amount of fuel necessary to maintain in the rail the level
of pressure required by the system as a function of the
engines operating conditions.
IMV effect
without IMV
with IMV
Torque (Nm)
Rail pressure = 80 bar
FUEL SYSTEM
DI ENG SM - 2004.9
Fuel temperature at
system backleak
without IMV
with IMV
Fuel Temp.(C)
2. Secondary, it allows the temperature to be reduced in

the fuel tank. When the excess fuel is discharged into
the back leak circuit, the pressure reduction in the fluid
(from rail pressure down to atmospheric pressure) gives
off a large amount of heat. This leads to a temperature
rise in the fuel entering the tank. In order to prevent too
high a temperature being reached, it is necessary to limit
the amount of heat generated by the fuel pressure
reduction, by reducing the back leak flow. To reduce the
back leak flow, it is sufficient to adapt the flow of the HP
pump to the engines requirements throughout its
operating range.
Torque (Nm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-20
Composition of IMV
The IMV is located on the hydraulic head of the pump. It is fed with fuel by the transfer pump via two radial holes. A
cylindrical filter is fitted over the feed orifices of the IMV. This makes it possible to protect not only the LP actuator, but
also all the components of the injection system located downstream of the IMV.
The IMV consists of the following components:
A piston held in the fully open position by a spring.
A piston filter located at inlet.
Two O-rings ensuring pressure tightness between the hydraulic head and the body of the IMV.
A body provided with two radial inlet holes and an axial outlet hole.
Coil
Transfer pump
Solenoid
Fuel
Filter
Spring
Piston
High pressure
Outlet hole
O-ring
Fuel
Transfer pump
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-21
Principle of Operation
The LP actuator is used to proportion the amount of fuel sent to the pumping element of the HP pump in such a way that
the pressure measured by the HP sensor is equal to the pressure demand sent out by the ECU. At each point of
operation, it is necessary to have:
Flow introduced into the HP pump = Injected flow + Injector backleak flow + injector control flow
The IMV is normally open when it is not being supplied with fuel. It cannot therefore be used as a safety device to shut
down the engine if required.
The IMV is controlled by current. The flow/current law is represented below.
Flow (I/hr)
Flow / Current Law
Current (mA)
Specifications
Piston stroke
1.4 mm
Diameter of holes
3.4 mm
Coil resistance
5.4 (at 25C)
Power supply
Battery voltage (It is prohibited to supply the IMV directly at the battery voltage
during the diagnostic test)
Max. current
1A
Weight
260 g
40C < T < 125C
Fluid temperature
40C < T < 90C
Control logic
Normally open without power (The flow decreases as the current rises).
ECU determines the value of the current to be sent to the IMV according to:
Engine speed
Flow demand
Rail pressure demand
Measured rail pressure
FUEL SYSTEM
DI ENG SM - 2004.9
E
C
Inlet Metering
Valve (IMV)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-22
HIGH FUEL PRESSURE LINE

High Pressure Pump
Description
This pump generates high fuel pressure and is driven by timing chain (radial plunger principle). This pump pressurizes
the fuel to approx. 1600 bar and sends this high pressurized fuel to high pressure accumulator (common rail) via high
pressure line.
It is possible to extend the pumping phase in order to considerably reduce drive torque, vibration and noise since the pump no
longer determines the injection period. The differences from conventional rotary pumps lies in the fact that it is no longer the
hydraulic head rotor which turns inside the cam, but the cam which turns around the hydraulic head. Thus, any problems of
dynamic pressure tightness are eliminated because the high pressure is generated in the fixed part of the pump.
1. IMV (Inlet Metering Valve)

2. Hydraulic Head
3. Plunger
4. Drive shaft and cam ring
5. Housing
6. Roller and shoe
7. Transfer pump
8. Fuel temperature sensor
Fuel
discharge
9. High fuel pressure - OUT

10. Pressure regulator
Fuel supply
Specifications
Maximum operating pressure: 1600 150 bar
Max. Overpressure: 2100 bar
Maximum sealing pressure: when using a plug instead of PRV, no leaks around pump outlet port (when applying
2500 bar of constant pressure)
Operating temperature: Continuously operating within temperature range of -30C ~ 120C in engine compartment
Inflowing fuel temperature: The maximum inflowing fuel temperature is 85C (continuously able to operate)
Pump inlet pressure: Relative pressure Min. - 0.48 bar (to end of filters lifetime)
Driving torque: 15 Nm / 1600 bar
Gear ratio (engine: pump): 0.625
Lubrication:
- Inside lubrication (rear bearing): Fuel

- Outside lubrication (front bearing): Engine oil
CHANGED BY
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-23
Principle of operation
During the filling phase, the rollers are kept in contact with the cam by means of coil springs mounted on either side
of each shoe. The transfer pressure is sufficient to open the inlet valve and to move the pumping plungers apart.
Thus, the dead volume between the two plungers fills with fuel.
When the diametrically opposite rollers simultaneously encounter the leading edge of the cam, the plungers are
pushed towards each other.
As soon as the pressure becomes higher than the transfer pressure, the inlet valve closes. When the pressure
becomes higher than the pressure inside the rail, the delivery valve opens. Consequently, the fuel is pumped under
pressure into the rail.
During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping element.
The valve closes as soon as the pressure in the pumping element becomes higher than the transfer pressure.
During the input phase, the ball of the delivery valve is subject to the rail pressure on its outer face and to the transfer
pressure on its inner face. Thus the ball rests on its seat, ensuring the pressure tightness of the body of the pumping
element. When the pressure in the element becomes higher than the pressure in the rail, the ball is unbalanced and
it opens. Fuel is then pumped into the rail at high pressure.
Roller
Plunger
<Fuel input>
<Pressurize>
This high pressure pump generates the driving torque with low peak torque to maintain the stress to driving components.
This torque is smaller than that of conventional injection pump, thus, only a small load will be applied to pump. The
required power to drive pump is determined by set pressure for rail and pump speed (delivery flow). Note that the fuel
leakage or defective pressure control valve may affect the engine output.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-24
Inlet valve and delivery valve
During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping element.
Under the effect of the transfer pressure, the two plungers are forced apart. When the rollers simultaneously encounter
the leading edge of the cam, pressure suddenly rises in the body. Of the pumping element. The valve closes as soon as
the pressure in the pumping element becomes higher than the transfer pressure. During the input phase, the ball of the
delivery valve is subject to the rail pressure on its outer face and to the transfer pressure on its inner face. Thus the ball
rests on its seat, ensuring the pressure tightness of the body of the pumping element. When the two diametrically
opposite rollers encounter the leading edges of the cam, the plungers are forced together and pressure quickly rises in
the body of the pumping element. When the pressure in the element becomes higher than the pressure in the rail, the
ball is unbalanced and it opens. The spring calibration is negligible compared with the pressure forces. Fuel is then
pumped into the rail at high pressure.
<Inlet valve>
<Delivery valve>
Lubrication and cooling of the HP pump

Lubrication and cooling of the pump are provided by the fuel circulation. The minimum flow required to ensure adequate
operation of the pump is 50 /h.
Phasing of HP pump required and offer 2 advantages

Conventional fuel injection pumps ensure pressurizing and distribution of the fuel to the different injectors. It is essential
to set the pump in such a way that the injection occurs at the required place during the cycle. The HP pump of the
common rail system is no longer used for the fuel distribution, it is therefore not necessary to set the pump in relation
to the engine.
Nevertheless, the setting or phasing of the pump offers two advantages:
It allows the torque variations of the camshaft and the pump to be synchronized in order to reduce the stresses on
the timing belt.
It allows pressure control to be improved by synchronizing peak pressures produced by the pump with pressuredrops caused by each injection.
This phasing allows pressure stability to be improved, which helps to reduce the difference in flow between the cylinders.
CHANGED BY
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-25
HP Pump Fuel Route

The fuel passed through the fuel filter is sent to the transfer pump via the HP inlet pump. this fuel passes through the
transfer pump by the transferring pressure and maintains the predefined value by the regulating valve in HP pump.
Also, this fuel gets into the IMV that controls only the fuel to the high pressure pump.
The below figure describes the pump operations when acceleration and deceleration.
When need high fuel pressure (acceleration)
IMV open
Venturi
to common rail
Fuel supply
to fuel tank
Backleak
Transfer pump
FUEL SYSTEM
DI ENG SM - 2004.9
High pressure pump
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-26
When do not need high fuel pressure (deceleration)
IMV close
Venturi
to common rail
Fuel supply
to fuel tank
Backleak
Transfer pump
High pressure pump
The fuel is sent to the high pressure side (hydraulic head) and compressed by the plunger. And, goes into the common
rail through the high pressure pipe.
The IMV installed in the high pressure side (hydraulic head) of HP pump precisely controls the fuel amount and delivers
the rail pressure feedback same as required amount.
The IMV is controlled by ECU.
Performance curve of HP pump

The time required to obtain a sufficient pressure in the rail to enable the engine to start depends on the volume of the
system (definition of the rail, length of the pipes, etc.). The aim is to reach a pressure of 200 bars in 1.5 revolutions (3rd
compression).
Rail pressure (bar)
Maximum operating pressure: 1600 150 bar
Engine speed (rpm)
<Pressure curve of HP pump>

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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-27
Sectional View of HP Pump
<Transfer Pump>
IMV valve
Drive shaft
<IMV Valve and High Pressure Pump (Drive Shaft)>

FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-28
Inlet valve
Temperature sensor
Shoe and roller
Delivery valve
<Inlet Valve, Delivery Valve, Shoe and Roller, Temperature Sensor>
<Hydraulic Head>
CHANGED BY
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-29
High Pressure Accumulator (Common Rail)
Description
The high pressure accumulator reserves the high pressure fuel. Simultaneously, the pressure changes due to the
delivery from HP pump and the fuel injection is diminished by rail volume. This high pressure accumulator is commonly
used in all cylinders. Even when a large amount of fuel leaks, the common rail maintains its internal pressure. This
ensures that the injection pressure can be maintained from when the injector opens.
Function
Relieve the pressure pulsation
Provide pressure information to ECU (fuel pressure sensor)
Specifications
Material: Forged Steel
Dimension: - Volume: 22 1cc
- Length: Max. 397.7 mm
- Outer diameter: 25.3 mm
Fuel pressure sensor Integrated type
- Sensor input voltage: 5 0.1V
- Sensor output signal voltage: - 4.055 0.125 V @ 1600 15 bar
- 0.5 0.04 V @ 0 bar
Operating pressure range
- Normal condition: 0 ~ 1600 bar
- Max. Overpressure: 2100 bar
Ambient temperature: - available within -40C ~ 125C
- Spontaneous max. temperature after engine stops: 140C (acceptable against total 15 hours)
Fluid temperature: -40 ~ 100C under normal operating conditions
Removal and installation: 10 times without any damage
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-30
No. 1
No. 2
No. 3
No. 4
No. 5
HP pipe
Injector
High fuel pressure pipe
Fuel rail
HP pump
<High pressure accumulator>
High Fuel Pressure Pipe

Function: Resistant to pressure changes, tightness against surroundings, supplying fuel through pump, rail and
injector with high pressure
Material: Steel (Zn Plated)
Common: Cylinder 1 & 3, 2 & 4, 5
Internal pressure
- Internal operating pressure: 0 ~ 1600 bar during its lifetime
- Spontaneous max. pressure when restoring: 2100 bar (max. total period: 20 hours)
- Bursting pressure: over 2500 bar
To keep cleanness and tightness, the high pressure pipe assembly should be used only once.
Notice
Make sure to replace the removed high fuel pressure pipes.

Tighten the fasteners with the specified tightening torque.
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-31

Preceding Work: Removal of engine cover
1. Disconnect the fuel pressure sensor connector.
Notice
Replace the fuel pipes with new ones.

Plug the openings of hole in the common rail with
sealing caps.
Check pressure is low before opening the circuit.
2. Unscrew the nuts and remove the fuel supply main pipe
from the fuel line.
Installation Notice
Tightening torque
40 10 Nm
Notice

sealing caps.
3. Unscrew the high fuel pressure line nuts and remove the
fuel pipes.
Installation Notice
Tightening torque
40 10 Nm
Notice

sealing caps.
4. Unscrew the bolts and remove the common rail
asssembly.
Installation Notice
Tightening torque
25 2.5 Nm
Notice

sealing caps.
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-32
Fuel Pressure Sensor
Fuel pressure sensor on the center of common rail detects instant fuel pressure changes and then sends to ECU. When
received these signals, ECU uses them to control fuel volume and injection time.
The fuel in the rail reaches to sensor diaphragm via blind hole in the pressure sensor and the pressure signal converts to
electrical signal. The signal measured by sensor will be amplified to input to ECU.
This piezo element type sensor changes pressure into electrical signal. Accordingly, when the shape of diaphragm
changes, electrical resistance in the layers on the diaphragm changes then can measure 0.5 ~ 5 V.
Sensor input voltage: 5 0.1 V
Output signal voltage of sensor
- 4.055 0.125 V: 1600 15bar
- 0.5 0.04 V: 0 bar
CHANGED BY
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-33
Pressure
Physical
changes
Sensing area
Amplifier
Converts to
electric signal
Electrically
amplyfying
signal
<Operation principle of fuel pressure sensor>
Upper area
Output
voltage
Lower area
Pressure (P)
<Sensor voltage>
Piezo resistance
Ground
SIG
REF 5V
Pressure sensor
<Circuit diagram of fuel pressuer sensor>
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-34
Temperature
Fuel Temperature Sensor
Resistance
<Fuel temperature sensor>
<Output characteristics of fuel temperature sensor>
Fuel temperature sensor is a NTC resistor that sends fuel temperature to ECU.
In case of NTC resistor, the resistance lowers if engine temperature rises so the ECU detects lowering signal voltages.
Fuel temperature sensor is installed on the fuel return line to correct pressure after measuring fuel temperature. 5V is
supplied to the sensor and voltage drop by temperature is delivered to ECU to measure the fuel temperature through
analog-digital converter (ADC).
Notice
Fuel temp sensor not to be dismounted.
Signal
Ground
<Circuit diagram of fuel temperature sensor>
HFM Sensor
- Refer to Intake System

- Refer to Engine Assembly
Knock Sensor
Camshaft Position Sensor

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-35
INJECTOR
The C2I labels including injector characteristics are attached in each injector. These C2I values should be input to ECU
by using SCAN-100 when replacing the ECU or injectors.
Special cautions:
1. Plug the openings of hoses and pipes with the sealing caps.
2. Replace the copper washer with new one plus injector holder bolt & washer.
3. Tighten the injector holder bolts with the specified tightening torque.
4. Be careful not to drop the injector.
Specifications
Length:
Injector body 181.35 mm

Injector nozzle 22.155 mm
Nozzle basic: 5 Holes, 146C Cone Angle,

840 mm3/min
Edge filter
Control: PWM type (solenoid injector)

Tightening: Clamping by fork
Leak off nipple
Fuel return: Nipple
C2I label
Nozzle holder body
Bobbin
C2I value
Control valve
Cap nut
Adaptor plate
Nozzle body
Washer
Nozzle needle
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-36
The maximum injection pressures are approximately 1,600 bar. The forces to be overcome in order to lift the needle of
the injector are therefore very large. Because of this, it is impossible to directly control the injector by using an electromagnetic actuator, unless very high currents are used, which would be incompatible with the reaction times required for
the multiple injections. The injector is therefore indirectly controlled by means of a valve controlling the pressurizing or
discharging of the control chamber located above the needle:
When the needle is required to lift (at the start of injection): the valve is opened in order to discharge the control
chamber into the back leak circuit.
When the needle has to close (at the end of injection): the valve closes again so that pressure is re-established in
the control chamber.
Valve
In order to guarantee response time and minimum energy
consumption:
Valve
Contact
making seal
Volume
under
high
pressure
Valve
Depressurization grooves
Spill
orifice
Volume under
vacuum
Spacer
INO inlet
irifice
SPO spill
orifice
The valve must be as light as possible.

The valve stroke must be as short as possible.
The effort needed to move the valve must be minimal, which
means that the valve must be in hydraulic equilibrium in
the closed position.
Spring pressure ensures contact between the valve and its
seat. To lift the valve, it is therefore required to overcome the
force being applied by this spring.
Spacer
The spacer is situated underneath the valve support. It integrates the control chamber and the three calibrated orifice
which allow operation of the injector. These orifices are:
The injector supply orifice (Nozzle Path Orifice: NPO)
The control chamber discharge orifice (Spill Orifice: SPO)
The control chamber filling orifice (Inlet Orifice: INO)
NOP nozzle
path orifice
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Control
chamber
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-37
Principle of Operation
Ff
Ff= =pressure * space
(Ff
rail * S)
(Ff==PPrail
S)
Fo = pressure * space
Fo ==Prail * S)
(Fo
(Fo = Prail
A)
Valve closed
Valve opens
Valve open
Valve closes
Valve closed
Needle closed
Needle closed
Needle opens
Needle open
Needle closed
No injection
No injection
Start of injection
End of injection
No injection
Injector at rest
The valve is closed. The control chamber is subject to the rail
pressure.
The pressure force applied by the fuel onto the needle is:
Ff = S * Prail
The needle is closed and hence there is no fluid circulation
through the NPO orifice. While static, the nozzle produces no
pressure drop. The cone of the needle is therefore subject to
the rail pressure. The force applied by the fuel to the needle is:
Fo = A * Prail
Since Ff > Fo, the needle is held in the closed position. There
is no injection.
Solenoid valve control

When the solenoid valve is energized, the valve opens. The
fuel contained in the control chamber is expelled through the
discharge orifice known as the Spill Orifice (SPO).
As soon as Ff > Fo, the needle remains held against its seat
and there is no injection.
FUEL SYSTEM
DI ENG SM - 2004.9
* S: The area of the flat upper surface of the injectors needle

* A: The area of the needle surface situated above the section
of contact between the needle and its seat
* Ff: The force applied by the fuel onto section S
* Fo:The force applied by the fuel onto section A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-38
Start of injection
As soon as Ff < Fo, or in other words:
Pcontrol < Prail * A/S
The needle lifts and injection begins. As long as the valve is open, the injectors needle remains lifted. When injection
begins, fuel circulation is established to feed the injector. The passage of the fuel through the inlet orifice of the injector
(similar to a nozzle) leads to a pressure drop which depends on the rail pressure.
When the rail pressure is at its highest (1600 bar), this pressure drop exceeds 100 bar. The pressure applied to the cone
of the needle (the injection pressure) is therefore lower than the rail pressure.
End of injection
As soon as the solenoid valve is de-energized, the valve closes and the control chamber is filled. Since the needle is
open, the thrust section areas situated on either side of the needle is therefore to apply different pressures to each of
these faces. The pressure in the control chamber cannot exceed the rail pressure, so it is therefore necessary to limit
the pressure applied to the needles cone. This pressure limitation is achieved by the NPO orifice which produces a
pressure drop when fuel is passing through it.
Prail * S
(Prail -
P) * S
When static, this pressure drop is zero. When the pressure in the control chamber becomes higher than the pressure
applied to the needles cone, the injection stops.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-39
Injecting Process
Fuel is delivered to the injector
Delivered fuel is passed

through supply orifice (1) and
control chamber orifice (2)
The fuel is delivered to the

volume under high pressure
through the spill orifice (3)
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-40
The fuel is delivered to the

control chamber (4) in spacer
The fuel begins to get into the

nozzle needle (5)
The nozzle needle is filled with

fuel and close the valve (6) by
increased pressure
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-41
The pressure is delivered to the

spill orifice (3)
The pressure is delivered to the

control chamber (7) and the
nozzle needle (8)
The nozzle needle starts to open

and inject the fuel
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-42
The nozzle needle blocks the

control chamber (9)
The valve opens due to the

pressure decreases (10)
The pressure is delivered to

control chamber (11)
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AFFECTED VIN
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-43
It pushes the nozzle needle and

the control chamber opens (12)
The nozzle closes (13)
FUEL SYSTEM
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI07-44
Fuel pressure
Fuel pressure
Minimum operating pressure: start injection over 100 bar
Maximum operating pressure: 1,600 bar (max. operating pressure in normal conditions)
Max overpressure: 2,100 bar
Maximum fuel volume at each injector cycle

Pilot Injection 5 mm3
Main Injection
85 mm3 (within 200 ~ 1,600 bar)
Main injection
Pilot injection
Small injection separation
Small injection separation: min. 200

(duration between the end of pilot injection and start of
main injection)
Opening delay definition
Opening Delay
10%
signal
amplitude
Injection rate
Injector drive pulse
10%
signal
amplitude
Adjustment of feedback injection volume: C2I
Time (
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
: Delayed time from applying operating voltage to start of

injection
FUEL SYSTEM
DI ENG SM - 2004.9
DI07-45
Injector control
Current
Peak pull current
= 22.0 A
Through pull
current = 7.5 A
Peak hold current

= 22.0 A
Through hold current
= 7.5 A
Time
Pull-in period
Hold period
The control current of the coil takes the following form:

The low current allows the Joule effect losses in the ECU and injector to be reduced. The call current is higher than the
hold current because during the hold phase.
The air gap between the valve and the coil is reduced and the electromagnetic force to be applied to the valve can
thus be reduced. It is no longer necessary to overcome the valve inertia.
Note
Joule Effect: The principle that the heat produced by an electric current is equal to the product of the resistance
of the conductor, the square of the current, and the time for which it flows.
I: current (A)
R: resistance ()
T: time (sec)
H: calori (cal)
Heat capacity (H) = 0.24 I 2RT
FUEL SYSTEM
DI ENG SM - 2004.9
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DI07-46
Fuel Injection
Other than conventional diesel engine, common diesel engine use two steps injection as follows:
Pilot Injection
Main Injection
In above two step injection, the fuel injection volume and injection timing is calibrated according to fuel pressure and fuel
temperature.
Pilot injection
Before starting main injection, a small amount of fuel is injected to help proper combustion. This injection is for reducing
the engine noise and vibration.
Angle of crankshaft
<Characteristic curve of discharge without pilot injection>
Needle lift (k)
Cylinder pressure (p)
Cylinder pressure (p)
Needle lift (k)
In other words, it makes the pressure increase in combustion chamber during combustion smooth to reduce the engine
noise and vibration (suppressing the surging). Basic values for pilot injection are adjusted according to the coolant
temperature and intake air pressure.
Angle of crankshaft
<Characteristic curve of discharge with pilot injection>
Main injection
Actual output from engine is achieved by main injection.
Pressure
The main injection determines the pilot injection has been occurred, then calculates the injection volume. Accelerator
pedal sensor, engine rpm, coolant temperature, intake air temperature and atmospheric pressure are basic date to
calculate the fuel injection volume in main injection.
1. Pilot injection
2. Main injection
1a. Ignition pressure with pilot injection
2a. Ignition pressure without pilot injection
Angle of crankshaft
<Characteristic curve of combustion chamber pressure during pilot injection>
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FUEL SYSTEM
DI ENG SM - 2004.9
DI07-47

Preceding Work: Removal of engine cover
1. Disconnect the injector return hose.
Notice
Plug the openings with sealing caps.

2. Remove the relevant connector for the injector.
3. Unscrew the bolts and remove the fuel pipes.

Installation Notice
Tightening torque
40 10 Nm

Plug the openings of the common rail with sealing
caps.
4. Unscrew the injector holder bolts.

Installation Notice
9 1.0 Nm
Tightening torque
180 10
Replace the bolts and washer with new ones.

5. Disconnect the injector holder.
6. Remove the injectors with a special tool.

Notice
Plug the openings of the injectors with sealing caps.
Pull the dropped washer out from the engine with
a special tool.
Clean carbon deposite in hole with specific tool.
8. Do not forget to update C2I with Scan 100 and cross old
C2I on label fitted on engine.
Notice
Replace the copper washer, holder bolts and washer
and fuel supply pipes with new ones.
FUEL SYSTEM
DI ENG SM - 2004.9
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DI07-48
ECU Wiring Diagram
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FUEL SYSTEM
DI ENG SM - 2004.9
DI07-49
REMOVAL AND INSTALLATION OF FUEL TANK

Preceding Works: Positioning the vehicle on the service lift and placing the chocks under the wheels
FUEL SYSTEM
DI ENG SM - 2004.9
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DI07-50
Components Locator
Fuel filler cap

Fuel sender cap
2-way cut valve
Fuel sender assembly
FFH supply tube

Air vent tube
Fuel filler assembly
Fuel
return line
Fuel
supply line
Wiring
Ventilation tube
Fuel tank module
Fuel tank strap
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FUEL SYSTEM
DI ENG SM - 2004.9
DI07-51
1. Disconnect the fuel supply hose, fuel return hose, FFH supply pipe and connector.
2. Unscrew the bolts and remove the fuel filler pipe from the fuel filler opening.
3. Install the safety jack under the fuel tank and remove the bolts (12mm x 4) from the fuel tank.
FUEL SYSTEM
DI ENG SM - 2004.9
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DI07-52
4. Carefully lower the safety jack with the fuel tank.
Caution
Be careful not to drop the fuel tank while removing it.
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FUEL SYSTEM
DI ENG SM - 2004.9
DI07-53
5. Remove the sender gauge assembly from the removed fuel tank.
(1) Disconnect the connector from the fuel tank cap.
(2) Remove the fuel hose (FFH fuel pump, Fuel supply)
(3) Remove the fuel sender gauge cap screw.
FUEL SYSTEM
DI ENG SM - 2004.9
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DI07-54
(4) Remove the fuel sender gauge assembly from the fuel
tank.
6. Always check the gauge operating conditions when replacing the components or repairing the system.
Caution
The fuel system (fuel tank) related operation may cause a fire. Always prepare the fire-fighting equipment
before starting the fuel system related operation.
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FUEL SYSTEM
DI ENG SM - 2004.9
DI08-1
SECTION
00 DI08
ENGINE CONTROL SYSTEM

Table of Contents
SENSORS FOR DIAGNOSIS ...................................... DI08-2
Engine ECU and other components ....................... DI08-2
Top view .................................................................. DI08-3
Side view ................................................................. DI08-4
ENGINE CONTROL SYSTEM ..................................... DI08-5
ECU ......................................................................... DI08-5
Fuel pressure control ........................................... DI08-11
Fuel injecstion control ........................................... DI08-12
Fuel flow control .................................................... DI08-13
Individual injector calibration (C2I) ....................... DI08-18
Minimum drive pulse (MDP) learning .................... DI08-20
Other components ................................................ DI08-21

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DI08-2
SENSORS FOR DIAGNOSIS

ENGINE ECU AND OTHER COMPONENTS
ECU/barometric
sensor
HFM sensor / intake air

temperature sensor
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Camshaft position
sensor
Fuel filter
(water sensor)
Preheating relay
Accelerator pedal
sensor
Main relay

DI ENG SM - 2004.9
DI08-3
TOP VIEW
Injectors (5)

DI ENG SM - 2004.9
Booster pressure
sensor
Glow Plugs (5)
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DI08-4
SIDE VIEW
Coolant temperature
sensor
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Knock sensors (2)
Fuel pressure
regulating valve
Crankshaft position
sensor

DI ENG SM - 2004.9
DI08-5

ECU
ECU receives signals from sensors through data line and then performs effective engine air-fuel ratio controls based on
those signals.
Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines
injection order and ECU detects drivers pedal position (drivers demand) through electrical signal that generated by
variable resistance changes in accelerator pedal sensor.
Air flow (hot film) sensor detects intake air volume and then transmits to ECU. Especially, the engine ECU controls the
air-fuel ratio by recognizing instant air volume changes through air flow sensor to pursue low emission gases (EGR valve
control). Furthermore, the ECU uses signals from coolant temperature and air temperature sensor, booster pressure
sensor and atmospheric pressure sensor as compensation signal to respond to injection start and pilot injection set
values and to various operations and variables.

DI ENG SM - 2004.9
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DI08-6
Pin No.
Description
Pin No.
Description
Engine ground
40
Fuel filter water detection sensor
Engine ground
41
RPM signal output
Main power (IG 1)
42
Main power (IG 1)
43
Main power (IG 1)
44
Knock sensor signal (#2)
Rail pressure sensor power supply
45
Knock sensor signal (#1)
46
Knock sensor ground (#1)
47
ECU power hold relay
48
10
49
11
50
12
ABD signal
Auto cruise result signal
51
52
13
53
ACC 1 sensor ground
15
54
CAN- H1
16
55
14
ACC 2 sensor ground
17
Auto cruise OFF
56
18
Auto cruise safety switch
57
ACC 2 sensor power supply
19
A/C pressure signal
58
Brake lamp switch
20
Fuel filter water detection warning lamp
59
21
Remote starter output
60
Vehicle speed indication lamp
22
Glow plug control
61
Preheater #1
23
Glow plug warning lamp
62
Preheater #2
63
Knock sensor ground (#2)

HFM sensor (air temperature sensor)
24
25
Rail pressure sensor signal
64
26
Rail pressure sensor ground
65
27
28
Engine ground
66
Engine ground
67
Auto cruise deceleration signal
29
68
30
69
31
Auto cruise acceleration signal
70
32
ACC 2 sensor signal
71
ACC 1 sensor signal
72
ACC 1 sensor power supply

CAN -LO
33
34
K-LINE #1
73
35
K-LINE #2
74
36
Vehicle speed sensor signal input
75
37
IG 1
76
A/C cycling pressure switch
38
Clutch pedal switch
77
Brake pedal switch
78
Trip computer
39
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DI ENG SM - 2004.9
DI08-7
Pin No.
Description
Pin No.
Description
79
A/C relay
101
Coolant temperature signal
80
Cooling fan LOW
102
Coolant temperature sensor ground
81
Cooling fan HIGH
103
Camshaft position sensor signal
82
Crankshaft position sensor (-)
104
Camshaft position sensor ground
83
HFM sensor (air mass sensor)
105
Engine check warning lamp
84
HFM sensor (ground)
106
85
107
Blower switch
86
HFM sensor (power supply)
108
Booster pressure sensor power supply
87
IMV (fuel pressure regulating valve)
109
Fuel temperature sensor signal
88
Engine ground
110
Fuel temperature sensor ground
111
Camshaft position sensor power supply
112
Immobilizer
91
113
Engine check warning lamp
92
114
Injector #1
93
115
Injector #4
94
116
Injector #3
89
90
Crankshaft position sensor (+)
95
Waste gate actuator
117
Injector ground (#1, 3, 4)
96
EGR valve
118
Injector ground (#2, 5)
97
119
98
120
Injector #5
121
Injector #2
99
Booster pressure sensor signal
100
Booster pressure sensor ground

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DI08-8
ECU InputsOutputs
Inputs
Control
Output

Atmospheric pressure sensor
(Built-in ECU)
Injector
Air flow sensor (HFM)
Fuel pressure regulating valve (IMV)
Electrical fan control (Low/High-speed)
EGR system

Fuel filter water sensor
Knock sensor
Glow plug relay
crankshaft position sensor

camshaft position sensor
A/C compressor relay
Immobilizer
Warning lights
(Water warning light, glow plug indica-
tor light, engine warning light)
Accelerator sensor
Preheater (auxiliary heater)
Vehicle speed sensor
K - line
Switch input signal
CAN communication
(IG, brake, clutch, A/C signal, A/C
Self-diagnosis
compressor)
Structure and Function of ECU

Function of ECU
ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels
and analyzes to control respective actuators.
ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft
angle based on input data and stored specific map to control the engine power and emission gas.
Output signal of the ECU microprocessor drives pressure control valve to control the rail pressure and activates
injector solenoid valve to control the fuel injection period and injection timing; so controls various actuators in
response to engine changes. Auxiliary function of ECU has adopted to reduce emission gas, improve fuel economy
and enhance safety, comforts and conveniences. For example, there are EGR, booster pressure control, autocruise
(export only) and immobilizer and adopted CAN communication to exchange data among electrical systems
(automatic T/M and brake system) in the vehicle fluently. And Scanner can be used to diagnose vehicle status and
defectives.
Operating temperature range of ECU is normally -40 ~ +85C and protected from factors like oil, water and electromagnetism and there should be no mechanical shocks.
To control the fuel volume precisely under repeated injections, high current should be applied instantly so there is
injector drive circuit in the ECU to generate necessary current during injector drive stages.
Current control circuit divides current applying time (injection time) into full-in-current-phase and hold-current-phase and
then the injectors should work very correctly under every working condition.
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DI ENG SM - 2004.9
DI08-9
Control Function of ECU

Controls by operating stages
: To make optimum combustion under every operating stage, ECU should calculate proper injection volume in
each stage by considering various factors.
Starting injection volume control
: During initial starting, injecting fuel volume will be calculated by function of temperature and engine cranking
speed.
Starting injection continues from when the ignition switch is turned to ignition position to till the engine reaches
to allowable minimum speed.
Driving mode control
: If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and engine rpm
and the drive map will be used to match the drivers inputs with optimum engine power.

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DI08-10
ECU - Removal and Installation

1. Flip up the front passengers seat and remove the ECU
cover nuts.
2. Remove the ECU bracket nuts.
3. Unscrew the ECU connect bolt and remove the ECU

assembly.

5. Backup the below data with SCAN-100 when replacing
the ECU.
- Current ECU data
- Vehicle Identification Number (VIN)
- Variant coding data
- Then, input the data into new ECU. For immobilizer
equipped vehicle, additional coding operation is
necessary.
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DI ENG SM - 2004.9
DI08-11
FUEL PRESSURE CONTROL

Fuel Pressure Control Elements
Pressure control consists of 2 principle modules.
Determines rail pressure according to engine operating conditions.
Controls IMV to make the rail pressure to reach to the required value.
Pressure in the fuel rail is determined according to engine speed and load on the engine. The aim is to adapt the
injection pressure to the engines requirements.
When engine speed and load are high
: The degree of turbulence is very great and the fuel can be injected at very high pressure in order to optimize
combustion.
When engine speed and load are low
: The degree of turbulence is low. If injection pressure is too high, the nozzles penetration will be excessive and part
of the fuel will be sprayed directly onto the sides of the cylinder, causing incomplete combustion. So there occurs
smoke and damages engine durability.
Fuel pressure is corrected according to air temperature, coolant temperature and atmospheric pressure and to take
account of the added ignition time caused by cold running or by high altitude driving. A special pressure demand is
necessary in order to obtain the additional flow required during starts. This demand is determined according to injected
fuel and coolant temperature.
Fuel Pressure Control

Rail pressure is controlled by closed loop regulation of IMV. A mapping system open loop determines the current
which needs to be sent to the actuator in order to obtain the flow demanded by the ECU. The closed loop will correct the
current value depending on the difference between the pressure demand and the pressure measured.
If the pressure is lower than the demand, current is reduced so that the fuel sent to the high pressure pump is
increased.
If the pressure is higher than the demand, current is increased so that the fuel sent to the high pressure pump is
reduced.
Flow demand
IMV current
Open
Engine speed
IMV
Current
Rail pressure
demand
Error
PIG
governor
Correction
Measured rail
pressure

DI ENG SM - 2004.9
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DI08-12
FUEL INJECSTION CONTROL

Fuel Injection Control
Injection control is used in order to determine the characteristics of the pulse which is sent to the injectors.
Injection control consists as below.
Injection timing
Injection volume
Translating fuel injection timing and injection volume into values which can be interpreted by the injector driver.
- a reference tooth (CTP)
- the delay between this tooth and the start of the pulse (Toff)
- the pulse time (Ton)
Main injection timing control

The pulse necessary for the main injection is determined as a function of the engine speed and of the injected flow.
The elements are;
A first correction is made according to the air and coolant temperatures.
This correction makes it possible to adapt the timing to the operating temperature of the engine. When the engine is
warm, the timing can be retarded to reduce the combustion temperature and polluting emissions (NOx). When the
engine is cold, the timing advance must be sufficient to allow the combustion to begin correctly.
A second correction is made according to the atmospheric pressure.
This correction is used to adapt the timing advance as a function of the atmospheric pressure and therefore the altitude.
A third correction is made according to the coolant temperature and the time which has passed since starting.
This correction allows the injection timing advance to be increased while the engine is warming up (initial 30 seconds).
The purpose of this correction is to reduce the misfiring and instabilities which are liable to occur after a cold start.
A fourth correction is made according to the pressure error.
This correction is used to reduce the injection timing advance when the pressure in the rail is higher than the
pressure demand.
A fifth correction is made according to the rate of EGR.
This correction is used to correct the injection timing advance as a function of the rate of exhaust gas recirculation.
When the EGR rate increases, the injection timing advance must in fact be increased in order to compensate for the
fall in termperature in the cylinder.
During starting, the injection timing must be retarded in order to position the start of combustion close to the TDC. To do
this, special mapping is used to determine the injection timing advance as a function of the engine speed and of the
water temperature. This requirement only concerns the starting phase, since once the engine has started the system
must re-use the mapping and the corrections described previously.
Pilot injection timing control

The pilot injection timing is determined as a function of the engine speed and of the total flow.
The elements are;
A first correction is made according to the air and coolant temperatures.
This correction allows the pilot injection timing to be adapted to the operating temperature of the engine.
This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the
altitude.
During the starting phase, the pilot injection timing is determined as a function of the engine speed and of the coolant
temperature.
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DI ENG SM - 2004.9
DI08-13
FUEL FLOW CONTROL

Main Flow Control
The main flow represents the amount of fuel injected into the cylinder during the main injection. The pilot flow represents
the amount of fuel injected during the pilot injection.
The total fuel injected during 1 cycle (main flow + pilot flow) is determined in the following manner.
: The drivers demand is compared with the value of the minimum flow determined by the idle speed controller.
When the driver depress the pedal, it is his demand which is taken into account by the system in order to
determine the fuel injected.
When the driver release the pedal, the idle speed controller takes over to determine the minimum fuel which
must be injected into the cylinder to prevent the enigne from stalling.
It is therefore the greater of these 2 values which is retained by the system. This value is then compared with the lower
flow limit determined by the ASR trajectory control system. As soon as the injected fuel becomes lower than the flow
limit determined by the ASR trajectory control system, the antagonistic torque (engine brake) transmitted to the drive
wheels exceeds the adherence capacity of the vehicle and there is therefore a risk of the drive wheels locking. The
system thus chooses the greater of these 2 values (main flow & pilot flow) in order to prevent any loss of control of the
vehicle during a sharp deceleration.
This value is then compared with the flow limit determined by the cruise control. As soon as the injected fuel becomes
lower than the flow limit determined by the cruise control, the vehicles speed falls below the value required by the driver.
The system therefore chooses the greater of these 2 values in order to maintain the speed at the required level.
This valve is then compared with the flow limit determined by the flow limitation strategy. This strategy allows the flow to
be limited as a function of the operating conditions of the engine. The system therefore chooses the smaller of these 2
values in order to protect the engine. This value is then compared with the fuel limit determined by the ASR trajectory
control system.
As soon as the injected fuel becomes higher than the fuel limit determined by the ASR trajectory control system, the
engine torque transmitted to the wheels exceeds the adhesion capacity of the vehicle and there is a risk of the drive
wheels skidding. The system therefore chooses the smaller of the two values in order to avoid any loss of control of the
vehicle during accelerations.
The anti-oscillation strategy makes it possible to compensate for fluctuations in engine speed during transient conditions.
This strategy leads to a fuel correction which is added to the total fuel of each cylinder. The correction is determined
before each injection as a function of the instantaneous engine speed.
A switch makes it possible to change over from the supercharge fuel to the total fuel according to the state of the engine.
Until the stating phase has finished, the system uses the supercharged fuel.
Once the engine changes to normal operation, the system uses the total fuel.
The main fuel is obtained by subtracting the pilot injection fuel from the total fuel.
A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. As soon as the
main fuel falls below this value, the fuel demand changes to 0 because in any case the injector is not capable of injecting
the quantity demand.

DI ENG SM - 2004.9
CHANGED BY
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AFFECTED VIN
DI08-14
Drivers request
Idle speed controller
ASR traction control
Cruise control
Flow limit
Speed limiter
ASR traction control

Engine status
Anti-oscillation strategy
Overflow
Programmed engine stop

Main flow < controllable min.flow
Pilot injection flow
Main flow request
0
Driver Demand
The driver demand is the translation of the pedal position into the fuel demand. It is calculated as a function of the pedal
position and of the engine speed. The driver demand is filtered in order to limit the hesitations caused by rapid changes
of the pedal position. A mapping determines the maximum fuel which can be injected as a function of the driver demand
and the rail pressure. Since the flow is proportional to the injection time and to the square root of the injection pressure,
it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the
engine cycle. The system compares the driver demand with this limit and chooses the smaller of the 2 values. The driver
demand is then corrected according to the coolant temperature. This correction is added to the driver demand.
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DI ENG SM - 2004.9
DI08-15
Idle Speed Controller

The idle speed controller consists of 2 principal modules:
The first module determines the required idle speed according to:
- The operating conditions of the engine (coolant temperature, gear engaged)
- Any activation of the electrical consumers (power steering, air conditioning, others)
- The battery voltage
- The presence of any faults liable to interface with the rail pressure control or the injection control. In this case,
the accelerated idle speed is activated to prevent the engine from stalling when operating in degraded mode.
- It is possible to increase or to reduce the required idle speed with the aid of the diagnostic tool.
The second module is responsible for providing closed loop control of the engines idle speed by adapting the
minimum fuel according to the difference between the required idle speed and the engine speed.
Flow Limitation
The flow limitation strategy is based on the following strategies:
The flow limitation depending on the filling of the engine with air is determined according to the engine speed and the
air flow. This limitation allows smoke emissions to be reduced during stabilized running.
The flow limitation depending on the atmospheric pressure is determined according to the engine speed and the
atmospheric pressure. It allows smoke emissions to be reduced when driving at altitude.
The full load flow curve is determined according to the gear engaged and the engine speed. It allows the maximum
torque delivered by the engine to be limited.
A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are
detected by the system. In this case, and depending on the gravity of the fault, the system activates:
- Reduced fuel logic 1: Guarantees 75 % of the performance without limiting the engine speed.
- Reduced fuel logic 2: Guarantees 50 % of the performance with the engine speed limited to 3,000 rpm.
- Reduce fuel logic 3: Limits the engine speed to 2,000 rpm.
The system chooses the lowest of all these values.
A correction depending on the coolant temperature is added to the flow limitation. This correction makes it possible to
reduce the mechanical stresses while the engine is warming up. The correction is determined according to the coolant
temperature, the engine speed and the time which has passed since starting.
Superchager Flow Demand

The supercharge flow is calculated according to the engine speed and the coolant temperature. A correction depending
on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during cold
starts. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool.
Pilot flow control

The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This amount is determined
according to the engine speed and the total flow.
A first correction is made according to the air and water temperature.
This correction allows the pilot flow to be adapted to the operating temperature of the engine. When the engine is
warm, the ignition time decreases because the end-of-compression temperature is higher. The pilot flow can therefore
be reduced because there is obviously less combustion noise when the engine is warm.
This correction is used to adapt the pilot flow according to the atmospheric pressure and therefore the altitude.
During starting, the pilot flow is determined on the basis of the engine speed and the coolant temperature.
DI ENG SM - 2004.9
CHANGED BY
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DI08-16
Cylinder Balancing Strategy

Balancing of the point to point flows
The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors.
The instantaneous speeds on two successive injections are first calculated.
The difference between these two instantaneous speeds is then calculated.
Finally, the time to be added to the main injection pulse for the different injectors is determined. For each injector,
this time is calculated according to the initial offset of the injector and the instantaneous speed difference.
Detection of an injector which has stuck closed

The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The difference in instantaneous
speed between 2 successive injections then exceeds a predefined threshold. In this case, a fault is signaled by the system.
Accelerometer Strategy
Resetting the pilot injection
The accelerometer is used to reset the pilot injection flow in closed loop for each injector. This method allows the
correction of any injector deviations over a period of time. The principle of use of the accelerometer is based on the
detection of the combustion noises.
The sensor is positioned in such a way as to receive the maximum signal for all the cylinders. The raw signals from the
accelerometer are processed to obtain a variable which quantifies the intensity of the combustion. This variable, known
as the ratio, consists of the ratio between the intensity of the background noise and the combustion noise.
A first window is used to establish the background noise level of the accelerometer signal for each cylinder. This
window must therefore be positioned at a moment when there cannot be any combustion.
The second window is used to measure the intensity of the pilot combustion. Its position is such that only the
combustion noises produced by the pilot injection are measured . It is therefore placed just before the main injection.
The accelerometer does not allow any evaluation of the quantity injected. However, the pulse value will be measured
when the injector starts injection and this pulse value is called the MDP (Minimum Drive Pulse). On the basis of this
information, it is possible to efficiently correct the pilot flows. The pilot injection resetting principle therefore consists of
determining the MDP, in other words the pulse corresponding to the start of the increase in value of the ratio (increase
of vibration due to fuel combustion).
Cylinder pressure
Needle lift
Major pilot injection
Ratio
Minor pilot injection
No pilot injection
No injection
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DI ENG SM - 2004.9
DI08-17
This is done periodically under certain operating conditions. When the resetting is finished, the new minimum pulse
value replaces the value obtained during the previous resetting. The first MDP value is provided by the C2I. Each
resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector.
Detection of leaks in the cylinders

The accelerometer is also used to detect any injector which may have stuck open. The detection principle is based on
monitoring the ratio. If there is a leak in the cylinder, the accumulated fuel self-ignites as soon as the temperature and
pressure conditions are favorable (high engine speed, high load and small leak).
This combustion is set off at about 20 degrees before TDC and before main injection.
The ratio therefore increases considerably in the detection window. It is this increase which allows the leaks to be
detected. The threshold beyond which a fault is signaled is a percentage of the maximum possible value of the ratio.
Because of the severity of the recovery process (engine shut-down), the etection must be extremely robust.
An increase in the ratio can be the consequence of various causes:
Pilot injection too strong
Main combustion offset
Fuel leak in the cylinder
If the ratio becomes too high, the strategy initially restricts the pilot injection flow and retards the main injection. If the
ratio remains high despite these interventions, this shows that a real leak is present, a fault is signaled and the engine
is shut down.
Detection of an accelerometer fault

This strategy permits the detection of a fault in the sensor or in the wiring loom connecting the sensor to the ECU. It is
based on detection of the combustion. When the engine is idling, the detection window is set too low for the combustion
caused by the main injection. If the ratio increases, this shows that the accelerometer is working properly, but otherwise
a fault is signaled to indicate a sensor failure. The recovery modes associated with this fault consist of inhibition of the
pilot injection and discharge through the injectors.

DI ENG SM - 2004.9
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DI08-18
INDIVIDUAL INJECTOR CALIBRATION (C2I)

Injected fuel is proportional to square root of injection time and rail pressure.
Delivery (mm3/st)
It is function between pulse and rail pressure and fuel injection curve is called injector characteristics curve having the
following shape.
Drive pulse (sec)
Common rail injectors are very accurate components. They are able to inject fuel delivery between 0.5 to 100 mg/str
under pressure varying from 150 to 1600 bar.
This high level of accuracy requires very low machining tolerances (few
).
Nevertheless, due to the machining dispersion, the loss of charge through the functional orifices, the friction between
moving parts and electromagnetic field level are different from one injector to the other. So, the difference of fuel delivery
for the same pressure and the same pulse can reach 5 mg/str from one injector to the other. It is impossible to control
efficiently the engine with such a dispersion between the different injectors. It is necessary to add a correction that
allows injecting the demanded fuel delivery whatever the initial hydraulic characteristics of the injector is. The method
consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of
the injector. So, the pulse should be corrected according to characteristics of each injector.
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DI ENG SM - 2004.9
DI08-19
C2I is composed of models on these characteristics of injectors.
C2I consists of 16-digit; composed of numbers from 1 to 9 and alphabets from A to F. ECU remembers C2I, characteristics of each injector, to make the most optimal fuel injection.
When replacing the injector, C2I code on the top of new injector should be input into ECU because the ECU is
remembering the injectors C2I value. If C2I is not input, engine power drops and occurs irregular combustion.
When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when
the accelerator pedal is depressed.
C2I Number
(16 digits)
C2I
value
For coding of C2I, refer to Diagnosis section

DI ENG SM - 2004.9
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DI08-20
MINIMUM DRIVE PULSE (MDP) LEARNING

When the pulse value that the injector starts injection is measured, it is called mininum drive pulse (MDP). Through MDP
controls, can correct pilot injections effectively. Pilot injection volume is very small, 1 ~ 2 mm/str, so precise control of
the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume precisely through
learning according to getting older injectors.
Learning Conditions
Coolant temperature
> 75C
Vehicle speed
> 50 Km/h (over 5 seconds)
Intake manifold pressure
> 0.7 bar
Engine speed
> 2,500 rpm
Battery voltage
10 V < MDP < 16 V
Fuel temperature
0 < fuel temperature < 80C
Initial MDP learning on each injector
5 seconds
Trouble Codes
Trouble code
Description
P1171
Fault MDP learning on injector No. 1
P1172
P1173
P1174
P1175
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Diagnosis
Check each injector

DI ENG SM - 2004.9
DI08-21
OTHER COMPONENTS
Accelerator Pedal Sensor
<Location of accelerator pedal sensor>
<When depressing the accelerator pedal

and brake pedal simultaneously>
Accelerator pedal sensor changes accelerator pedal position into electrical signal and then sends to ECU to let know
the drivers demand. There are 2 sensors in the accelerator pedal sensor. Accelerator pedal No.1 (ACC 1) sensor signal
determines fuel injection volume and injection timing during driving, and accelerator pedal No. 2 (ACC 2) sensor signal
compares whether the No. 1 sensor signal value is correct.
If accelerator pedal No. 1 and 2 sensors are defective, ECU remembers defect code, and acceleration responses are
getting bad and engine rpm hardly increases.
Notice
When depressing the accelerator pedal and brake pedal simultaneously while driving, the acceleration response
will be diminished abruptly and cannot drive with over 70 km/h even though depressing the accelerator pedal
to its end. At this time, the trouble code of P-1124 Accelerator pedal sensor stuck is stored into ECU. If
depressing the accelerator pedal over 3 times, it will be resumed to normal condition.
* For detailed information, refer to Diagnosis section in this manual.
Signal 1
Ground
Signal 2
Ground
<Circuit diagram of Accelerator pedal sensor>

DI ENG SM - 2004.9
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DI08-22
Temp.
Resistance
<Coolant temperature sensor>
<Output characteristics of coolant temperature

sensor>
Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects lowering
signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if engine
temperature is too low, the fuel injected as foggy state forms big compounds causing incomplete combustion. So the
sensor detects coolant temperature and changes coolant temperature changes into voltage then sends to ECU to
increase the fuel volume during cold start for better starting. And detects engine overheating for fuel volume reduction to
protect the engine.
ECU functions as below with coolant temperature sensor signals.
When engine is cold, controls fuel volume to correct idle speed.
When engine is overheated, controls electrical fan and A/C compressor to protect the engine.
Sends information for emission control.
Temperature (C)
)
NTC 1 Resistance (
)
NTC 1 Resistance (
20
2,550
6,062
50
826
1,800
80
321
638
120
123
200
Signal
Auto amp
Ground
<Circuit diagram of coolant temperature sensor>

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DI ENG SM - 2004.9
DI08-23
Boost Pressure Sensor
Not using terminals
<Location of boost pressure sensor>
<Boost pressure sensor>
Boost pressure sensor uses piezo element and uses only 3 terminals out of 6.
It sets fuel injection timing and corrects fuel injection volume according to atmospheric pressure.
Output voltage calculation
VO = VS x ( P x 0.004 - 0.04)
VO : Output voltage
VS : Supply voltage
P : Applying voltage
Voltage (V)
The other function is determining EGR operation stops.
Pressure (bar)
<Output characteristics of sensor>

Performance proofing pressure range
20 ~ 250 KPa
Performance proofing temperature range
- 40 ~ 110C
Storage proofing temperature range
- 40 ~ 125C
Performance proofing supply voltage
4.85 ~ 5.35 V
Max. consuming current
10 mA (supply voltage at 5.35 V)
Responsibility
Tightening torque

DI ENG SM - 2004.9
TR
7ms
10 Nm
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DI08-24
Ground
REF 5V
SIG
<Circuit diagram of booster pressure sensor>
Vehicle Speed Sensor

The ABS or ESP control unit sends the vehicle speed signals to ECU. ECU uses these signals to calculate the vehicle
speed and meter cluster shows signals as vehicle speed.
Function
- Limits idle control correction duty range
- Controls cooling fan
- Cuts fuel injection if exceeds max. speed
ABS
or
ESP control unit
- Controls vehicle shifting feeling

- Used for exhaust gas control mode
CAN communication
<Circuit diagram of vehicle speed sensor>
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DI ENG SM - 2004.9
DI08-25
Barometric Pressure Sensor

It is built-in the ECU and detects absolute pressure of atmosphere to correct fuel injection timing and injection volume
according to altitude.
Other switches
Brake switch
Brake switch detects brake pedal operations and then sends to engine ECU. It has dual structure with 2 combined
switches and there are brake switch 1 and 2. When these 2 signals are input, engine ECU recognizes as normal brake
signals. These switch signals are related with accelerator pedal sensor operations and used to control the fuel volume
during braking. It means there are no problems in operating accelerator pedal when the brake pedal is operated but the
fuel volume reduces if operates brake pedal while the accelerator pedal is depressed.
Brake pedal switch (NC)
Brake lamp switch (NO)
<Brake switch circuit>
Clutch pedal switch

Clutch pedal switch is installed on the upper of the clutch and sends clutch pedal operations to engine ECU. Contact
type switch allows engine ECU to recognize the shifting points to correct the fuel volume. It means it corrects fluctuation
happens during gear shifting. Another different function is canceling auto cruise function if equipped (auto cruise control
- equipped for export).
Clutch pedal switch (NO)

Engine
ground
<Clutch pedal switch circuit>

DI ENG SM - 2004.9
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DI09-1
SECTION
00 DI09
ELECTRIC DEVICES
AND SENSORS
Table of Contents
ELECTRIC DEVICES AND SENSORS ........................ DI09-2
Sensors in engine compartment ............................. DI09-2
Electric devices in engine compartment ................. DI09-3
Specifications .......................................................... DI09-4
Circuit diagram of preheating system ..................... DI09-5
Circuit diagram of starting and alternator .............. DI09-6
TROUBLE DIAGNOSIS ............................................... DI09-7
General ................................................................... DI09-7
Alternator ................................................................ DI09-9
Starter ................................................................... DI09-11
Preheating system ................................................ DI09-13
Preheating time relay ............................................ DI09-15
Glow plug .............................................................. DI09-16
SPECIAL TOOLS AND EQUIPMENT ........................ DI09-18
ELECTRIC DEVICES AND SENSORS

DI ENG SM - 2004.9
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DI09-2

SENSORS IN ENGINE COMPARTMENT
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Booster pressure
sensor
Camshaft position
sensor
Oil pressure switch
Coolant temperature
sensor
Crankshaft position
sensor
Fuel temperature
sensor
Knock sensor

DI ENG SM - 2004.9
DI09-3
ELECTRIC DEVICES IN ENGINE COMPARTMENT
Alternator
Glow plug
Capacity
PTC equipped vehicle
: 12V - 140A
FFH equipped vehicle
: 12V - 115A
Air conditioner compressor

DI ENG SM - 2004.9
Starter
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DI09-4
SPECIFICATIONS
Description
Starter
Unit
Specification
WP220
Kw
2.2
160
rpm
4500
rpm/A
1700/430
Brush length
mm
18
Armature diameter
mm
55
Armature run-out
mm
0.1
Segment groove depth
mm
21.7
NP37
V/A
PTC equipped vehicle: 12V-140A
Type
Output power
No load test @ 12 volts
Drive pinion speed at no load
Drive pinion speed at load
Alternator
Type
Output voltage / current
FFH equipped vehicle: 12V-115A

Regulator type
Regulating voltage
14.6
mm
12.5
mm
MF
Capacity
AH
12V - 90AH
Rupture capatity
RC
160
Type
Seized type
Rated voltage
11.5
Circuit connection
Parallel
sec
Max. 60 ~ 90
Brush
Length
Quantity
Wear limit
Battery
Glow plug
Type
Preheating time
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DI ENG SM - 2004.9
DI09-5
CIRCUIT DIAGRAM OF PREHEATING SYSTEM

DI ENG SM - 2004.9
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DI09-6
CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR
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DI ENG SM - 2004.9
DI09-7
TROUBLE DIAGNOSIS
GENERAL
Condition
No crank
Crank ok, but too slow
Starter motor does not stop
Starter motor running, but not

cranking
Battery discharge
Charging indicator lamp does not

work when the ignition switch on
(engine does not work)
Charging indicator lamp does not

put out lights after starting the
engine
Battery over charging

DI ENG SM - 2004.9
Probable Cause
Correction
Low battery voltage.
Charging the battery or replace

the battery.
Battery cable is loose,

corroded, or damaged.
Repair or replace the battery

cable.
Faulty starter motor or starter

motor circuit is open.
Repair or replace the starter

motor/starter motor circuit.
Faulty ignition switch.
Replace the ignition switch.
Ground short.
Repair the ground short.
Low battery voltage.
Charging the battery or replace

the battery.
Battery cables are loose,

corroded, or damaged.

cable.
Faulty starter motor.

motor.
Faulty starter motor.

motor.
Broken the clutch pinion gear or

faulty starter motor.
Replace the starter motor.
Broken the flywheel ring gear.
Replace the flywheel.
Connected circuit is open.
Repair the open circuit.
Loosen the generator drive belt.
Adjust the belt tension or replace

the belt.
The circuit is open or a short.
Repair the open or a short circuit.
Battery run down.
Replace the battery.
Open ground circuit.
Repair the open ground circuit.
Charging indicator lamp is blown

or fuse is blown.
Repair or replace the charging

indicator lamp/fuse.
Alternator ground circuit is open

or a short.
Repair the circuit.
Battery cable is corroded or

damaged.

cable.
Loosen the generator drive belt.
Adjust the belt tension or replace

the belt.
Faulty wiring harness.
Repair the wiring harness.
Alternator voltage regulator faulty
Replace alternator
Voltage detecfing wiring faulty
Repair wiring
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DI09-8
Symptom
Hard engine starting
Unstable engine idling
Enging acceralation malfunction
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Cause
Action
Ignition coil faulty
Replace ignition coil
Spark plug malfuntion
Replace spark plug or adjust

clearance
Ignition timing faulty (spark plug

light is normal)
Resetting valve timing
Spark plug malfunction
Replace spark plug or adjust

clearance
Ignition coil faulty
Replace ignition coil
Ignition timing faulty
Ignition timing faulty

DI ENG SM - 2004.9
DI09-9
ALTERNATOR
1. Viscous clutch
3. Alternator
2. Bolt ............................................................. 45 Nm
4. Plug connection

DI ENG SM - 2004.9
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DI09-10

2. Remove the plug connection.
3. Unscrew the bolts and remove the alternator.

Installation Notice
Tightening torque
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DI ENG SM - 2004.9
DI09-11
STARTER
1. Starter
3. Nut .................................................................... 15 Nm
2. Washer
4. Bolt ................................................................... 48 Nm

DI ENG SM - 2004.9
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DI09-12

2. Disconnect the starter terminal.
3. Lift up the vehicle and remove the front propeller shaft

mounting bolts.
4. Remove the upper and lower mounting bolts.
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DI ENG SM - 2004.9
DI09-13
PREHEATING SYSTEM
General
- Preheating warning light
Coolant
temperature
sensor

DI ENG SM - 2004.9
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DI09-14
Function
Preheating system controls and checks following functions and operating conditions.
Pre-heating
: The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from
the battery and there are normal communications with ECU. The surface of glow plug will be heated up to 850C
very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
Preheating time is controlled by ECU.
While engine starting
: Help to warm up engine
After-heating
: When the engine is started, after-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.
After-heating time is controlled by ECU.
Checking glow plugs
- Check each glow plug for short in circuit
- Check each glow plug for open in circuit due to overvoltage
- Check glow plug for short to ground
Forceful relay shut-down
- When glow plug is shorted to ground
K-Line communication
- ECU sends the results to preheating time control relay through K-Line to start communication.
- Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
- Glow plug makes communication only as response to demand.
- The ECU will attempt to read the diagnostic information 2 seconds after power up.
- Under the following conditions, communication error occurs.
When there is no response from glow plug module within 50 milli-second after request of ECU.
When an error is detected in checksum
Less byte is received
Error code of Pre heating control communication fail will be reported.
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DI ENG SM - 2004.9
DI09-15
PREHEATING TIME RELAY

Structure
K-LINE #1
(ECU 34)
IG1 power
terminal
Glow plug control

signal
(ECU 113)
Ground
terminal
B+ main
wire (12V)
Glow plug terminal
#1 ~ #5
Specifications
Description
Specification
Rated voltage
DC 12 V
DC 8 ~ 15 V
Operating range
- 40 ~ + 100C
Relay operating voltage
Over 6.5 V
Relay releasing voltage
Over 1.5 V
Relay coil resistance
11.3
Voltage drop
Below 150 mV at each glow plug (at 16A of current)
Parasitic current
Max. 1mA

DI ENG SM - 2004.9
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DI09-16
GLOW PLUG
Cylinder type glow plug is inserted into the cylinder and composed of heating pin and housing.
There are heating coil and control coil in the heating pin and
those coils located inside of ceramic cover turn ON or OFF
the internal switch.
Purposes of use
- Preheating before engine starting
- During engine starting
- After-heating after engine starting
Conditions for glow plugs

- Prompt heating and secured temperature stabilities (temperature changes) in low operating voltage
- Should not exceed permissible max. temperature under max. operating voltage
- Heating pin should have good heat-resisting properties against combustion gas and durability
- Material of the glow plug should meet high stressing conditions (e.g., temperature, vibration and environmental
factors)
Specifications
Description
Specification
Rated voltage
11 0.1 V
Current consumption
Preheating time
Initial current I
T
850C
intial
< 30.0 A
= 5 1.5 sec.
(From ambient temperature up to 85C)

900 C
Tightening torque
15 + 3 Nm
Trouble Code
Refer to Diagnosis section in this manual.
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DI ENG SM - 2004.9
DI09-17

1. Turn the ignition switch to OFF position and disconnect
the negative battery cable.
2. Set aside the harnesses on the cylinder head.
3. Disconnect the glow plug connectors and loosen the glow

plugs.
Installation Notice
Tightening torque
4. Remove the glow plugs from the cylinder head with a

special tool. Plug the openings of the glow plugs with
sealing caps.

DI ENG SM - 2004.9
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DI09-18

Glow plug remover
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Application
Removal of glow plug

DI ENG SM - 2004.9
DI10-1
SECTION
00 DI10
DIAGNOSIS
Table of Contents
SCAN-100 OPERATING PROCEDURES D27DT ENGINE ........................................................... DI10-3
TROUBLE DIAGNOSIS TABLE ................................. DI10-25
FUEL SYSTEM DIAGNOSIS ................................... DI10-179
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-3
SCAN-100 OPERATING PROCEDURES - XDi270 ENGINE
ENTERING DIAGNOSIS PROCEDURES .................... DI10-4

FUNCTION SELECTION ............................................. DI10-6
Check the trouble code .......................................... DI10-6
Sensor data check .................................................. DI10-7
Actuator check ........................................................ DI10-8
Trouble code clear ................................................ DI10-10
ECU identification .................................................. DI10-12
Injector (C2I) corrections ...................................... DI10-13
Leak detection ...................................................... DI10-15
Variant coding ....................................................... DI10-16
ECU replace .......................................................... DI10-18
Rail pressure reset ............................................... DI10-23
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-4
SCAN-100 OPERATING PROCEDURES - D27DT ENGINE

ENTERING DIAGNOSIS PROCEDURES
1. Select 1] DIAGNOSIS and press
screen.
2. Select 6] STAVIC and press

SELECTION screen.
3. Select 1] ECU and press

SELECTION screen.
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in MAIN MENU
in VEHICLE
in CONTROL UNIT
DIAGNOSIS
DI ENG SM - 2004.9
DI10-5
4. The FUNCTION SELECTION screen is displayed.
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-6
FUNCTION SELECTION
Check the Trouble Code
Preceding work: Perform the Entering Diagnosis Procedures
1. Select 1] TROUBLE CODE and press ENTER in

FUNCTION SELECTION screen.
2. The DIAGNOSTIC TROUBLE CODEs screen is

displayed and it shows the trouble.
Note
If there is not any fault, NO TROUBLE DETECTED

message appears.
3. When selecting a trouble code, then
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if you press
: Displays the sensor data for the

detected trouble (Freeze Frame
Mode).
if you press
: Displays the help tips for the

detected trouble.
DIAGNOSIS
DI ENG SM - 2004.9
DI10-7
Sensor Data Check

Preceding Work: Perform the Entering Diagnosis Procedures
1. Select 2] DATA LIST and press

SELECTION screen.
in FUNCTION
2. The screen shows approx. 58 sensor data.
3. Select the items you want to see and press

to freeze them.
key
Note
You can freeze up to 5 items (*: selected items).
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-8
Actuator Check
1. Select 3] ACTUATOR and press

SELECTION screen.
in FUNCTION
2. The screen shows 19 items. Select the item you want to

see and press
.
3. For example, if you select 02] GLOW PLUG item and

press
, the screen as shown in figure is displayed.
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DIAGNOSIS
DI ENG SM - 2004.9
DI10-9
4. If you want to operate the glow plug relay, press
key. The OPERATING message appears and the relay

operation alarm sounds.
5. If you want to stop the operation press

keyboard.
DIAGNOSIS
DI ENG SM - 2004.9
key in
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DI10-10
Trouble Code Clear

1. Select 1] TROUBLE CODE and press

in
2. The DIAGNOSTIC TROUBLE CODEs screen is

displayed and it shows the trouble.
Note
C = Current trouble, H = History trouble
3. Fix the trouble and go back to 1] TROUBLE CODE

screen and check if the trouble has been changed to H
(History trouble code) code.
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DIAGNOSIS
DI ENG SM - 2004.9
DI10-11
4. If the trouble has been change to H (History trouble code)
code, press
key to go back to FUNCTION
SELECTION screen. In this screen, select 4] TROUBLE
.
CODE CLEAR and press
5. The TROUBLE CODE CLEAR screen is displayed. If

you press
, only the history trouble codes will be
cleared.
Note
Current trouble codes will not be cleared.
Check the trouble codes after clearing the trouble
codes.
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-12
ECU Identification
1. Select 5] ECU IDENTIFICATION and press

in
2. The ECU IDENTIFICATION screen that shows the VIN,

ECU software number, ECU software version and
programming date is displayed.
3. If you replaced the ECU, press

identification number.
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to input the vehicle
DIAGNOSIS
DI ENG SM - 2004.9
DI10-13
Injector (C2I) Corrections

Notice
If the injector/ECU has been replaced or the injector system

defective is suspected, go to C2I Coding item and check
the injector and coded injector C2I value.
1. Select 6] INJECTOR (C2I) CORRECTIONS and press
in FUNCTION SELECTION screen.
2. The INJECTOR (C2I) CORRECTIONS screen that shows

current C2I coding values of #1 to #5 injector is displayed.
3. If you replaced the ECU, enter the C2I value of the relevant
injector.
Note
The C2I value of replacing injector is recorded in
the label.
C2I coding number: 16 digits (ex, B1 B9 D4 1B 43
C6 0E 4F)
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-14
3-1. If you enter the invalid C2I value of the relevant injector,
the message as shown in figure appears with alarm sound.
Note
If you want to go back to previous screen, press
key. You can see the previous C2I value.
3-2. If you enter the valid C2I value of the relevant injector, the
message as shown in figure appears with alarm sound.
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DIAGNOSIS
DI ENG SM - 2004.9
DI10-15
Leak Detection
Note
This item is for checking the high fuel pressure after the
IMV supply line of HP pump in DI engine fuel system. If
you still suspect that the fuel pressure system is defective
even after no trouble is detected, perform the fuel pressure
test again by using a fuel pressure tool kit.
1. Select 7] LEAK DETECTION and press

in
2. The LEAK DETECTION screen that shows the checking

conditions as shown in figure is displayed.
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-16
Variant Coding
1. Select 8] VARIANT CODING and press

in
2. When the VARIANT CODING screen is displayed,

select 1] READ VARIANT VALUE and press
.
3. The VARIANT CODING screen that shows currently

equipped devices is displayed.
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DIAGNOSIS
DI ENG SM - 2004.9
DI10-17
4. If you need to change the variant coding, press
key to go back to VARIANT CODING screen. In the

screen, select 2] WRITE VARIANT CODING and press
5. When the WRITE VARIANT CODING VALUE screen is

displayed, change the item by using arrow keys.
6. If you press
, the message as shown in figure
appears. And, then VARIANT CODING screen is
displayed.
7. Select READ VARIANT VALUE to see the coding coded

value.
DIAGNOSIS
DI ENG SM - 2004.9
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DI10-18
ECU Replace
1. Select 0] ECU REPLACE and press
in
2. Before starting ECU replace, check the ECU S/W version

of old ECU and new ECU.
3. When the ECU REPLACE (STEP 2) screen is displayed

followed by ECU REPLACE (STEP 1) screen, turn the
ignition OFF and remove the currently installed ECU.
Notice
Do not turn off the Scan-100 at this time.

Record the below data:
- Vehicle identification number
- Variant coding value
- C2I coding value
- Multi calibration
4. Install the new ECU.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-19
, the message as shown in figure 1 (system
4. If you turn the ignition switch to ON position and press
initialization) appears, and then MULTI CALIBRATION screen (figure 2) is displayed.
figure 1
figure 2
5. In MULTI CALIBRATION screen, select the relevent

model.
, the processing message as

6. When you press
shown in figure appears.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-20
7. If the multi calibration is completed successfully, ECU
REPLACE (STEP 5) screen is displayed.
Backup data:
- Multi calibration value
- VIN value
- Variant code value
- Injector (C2I) value
8. In immobilizer equipped vehicle, the immobilizer coding

should be done after completed the multi calibration.
9. Press
and enter the user password.
10. If the password is invalid, the access denied screen as

shown in figure is displayed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-21
11. If the password is valid, an immobilizer coding is started.
12. If you want to code for additional keys, remove the first
key from key switch and insert the second key. Turn it
to ON position and press
to proceed.
13. You can code up to five keys with same manner.
.
14. When the immobilizer coding is completed, press
The completion message as shown in figure appears.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-22
15. When you turn the ignition key to OFF position, the
message screen as shown in figure is displayed. Wait
for 15 seconds and turn the ignition key to ON position.
16. Press
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
to return to MAIN MENU screen.
DIAGNOSIS
DI ENG SM - 2004.9
DI10-23
Rail Pressure Reset

Rail Pressure Reset Procedures
The engine ECU needs a specific amount of fuel according to the fuel supply lines and vehicle driving conditions.
However, if the fuel supply (pressure) is not achieved due to, for instance, defective fuel system, ECU designates the
offset value to the high pressure pump to compensate it.
The fuel supply pressure varies according to the offset value and the engine output could be decreased due to this
variation. When the engine output decreases, check whether all rail pressure offset values is set to 0 in the Rail
Pressure Reset screen in SCAN-100. If the setting value is not 0, measure the fuel pressure with a tester. If any
defective is found, repair the affected components and reset the rail pressure offset value to 0.
The rail pressure reset procedures should be done after replacing any high pressure pump and fuel system
related components.
1. Select the vehicle model.
2. Select [RAIL PRESSURE RESET] in [FUNCTION

SELECTION] screen.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-24
3. Enter the current rail pressure value and press [ENTER]
to reset the offset value.
4. The screen returns back to step 3 after displaying the

[RAIL PRESSURE RESET IS SUCCESSFUL] message.
Notice
If the offset value is not set to 0, check the fuel

pressure and other DTC generations before starting
the rail pressure reset operation.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-25
TROUBLE DIAGNOSIS TABLE
INDEX OF DTC ..................................................... 10D-26, 73

Trouble diagnosis table ......................................... 10D-29
Trouble diagnosis procedures ............................... 10D-77
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-26
INDEX OF DTC
P0102 Low HFM Sensor Signal (Circuit Open) .......... DI10-29
P1291 High Resistance for Injector #3 wiring harness .. DI10-40
P0103 High HFM Sensor Signal (Circuit Short) .......... DI10-29
P0704 Clutch switch malfunction ............................. DI10-40
P0100 Air Mass Flow (HFM) Malfunction .................. DI10-30
P1115 Coolant Temperature Sensor Malfunction ....... DI10-41
P0344 Cam Position Sensor Malfunction
P0118 Coolant Temperature Sensor
(Cam Signal Missing) ..................................... DI10-30
P0341 Cam Position Sensor Malfunction

(Poor Synchronization) .................................. DI10-30
P0219 Too Small Clearance of Crank Angle Sensor .. DI10-30
Malfunction - Short ........................................ DI10-41
P0117 Coolant Temperature Sensor

Malfunction - Open ........................................ DI10-42
P0115 Supply Voltage Fault to Coolant
P0336 Too Large Clearance of Crank Angle Sensor . DI10-31
Temperature Sensor ...................................... DI10-42
P0372 Crank Angle Sensor Malfunction .................... DI10-31
P0685 Main Relay Malfunction .................................. DI10-42
P1107 Barometric Sensor Circuit Short/GND Short ... DI10-31
P1405 EGR Solenoid Valve Short Malfunction - Short to ground
P1108 Barometric Sensor Circuit Short ..................... DI10-31

P1105 Barometric Sensor Circuit Short ..................... DI10-31
...................................................................... DI10-42
P1406 EGR Solenoid Valve Malfunction - Short to +batt
P0562 Low Battery Voltage ...................................... DI10-32
...................................................................... DI10-42
P0563 High Battery Voltage ...................................... DI10-32
P1480 Condenser Fan #1 Circuit Malfunction - Open . DI10-43
P0560 Battery Voltage Malfunction ........................... DI10-32
P1481 Condenser Fan #1 Circuit Malfunction - Short . DI10-43
P0109 Low Booster Pressure Sensor Signal ............ DI10-33
P1482 Condenser Fan #1 Circuit Malfunction -
P0106 High Booster Pressure Sensor Signal ............ DI10-33
Short to Ground ............................................. DI10-43
P0107 Booster Pressure Sensor Open/GND Short ... DI10-34
P1526 Condenser Fan #2 Circuit Malfunction - Open . DI10-43
P0108 Booster Pressure Sensor Short ..................... DI10-34
P1527 Condenser Fan #2 Circuit Malfunction - Short . DI10-43
P0105 Supply Voltage Fault to Booster
P1528 Condenser Fan #2 Circuit Malfunction -
Pressure Sensor ............................................ DI10-35
P1106 Booster Pressure Sensor Malfunction ........... DI10-35

P1109 Booster Pressure Sensor Initial Check Fault . DI10-36
P0571 Brake Pedal Switch Fault ............................... DI10-36
P0325 Accelerometer #1 (Knock Sensor)

Malfunction .................................................... DI10-44
P0330 Accelerometer #2 (Knock Sensor)
P1572 Brake Lamp Signal Fault ................................. DI10-37
Malfunction .................................................... DI10-44
P1571 Brake Lamp Signal Fault ................................. DI10-37
P1611 Injector Bank #1 Malfunction - Low Voltage ... DI10-44
P1286 Low Resistance for Injector #1 wiring harness . DI10-37
P1612 Injector Bank #1 Malfunction - High Voltage ... DI10-45
P1618 Injector Bank #2 Malfunction - Low Voltage ... DI10-45
P1619 Injector Bank #2 Malfunction - High Voltage .. DI10-45
P0263 Injector #1 Balancing Fault ............................. DI10-46
P0201 Injector #1 Circuit Open .................................. DI10-46
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-27
P0202
Injector #2 Circuit Open ................................. DI10-46
P0204
Injector #4 Circuit Open .................................. DI10-47
P0205
P0203
P1201
Injector #1 Circuit Short .................................. DI10-47
P1202
P1204
P1171
#1 Injector MDP Malfunction ........................... DI10-57
P1205
P1172
P1203
P1174
P0182
Fuel temperature sensor - Short to Ground ... DI10-48
P1175
P0183
Fuel temperature sensor - Short to B+ ........... DI10-48
P1173
P0180
Fuel temperature sensor - Malfunction .......... DI10-49
P1252
Too High IMV Pressure ................................... DI10-58
P1678
Glow Plug Drive Malfunction - Open .............. DI10-49
P1120
Accelerator Pedal Sensor #1 Malfunction ..... DI10-58
P1679
Glow Plug Drive Malfunction - Short .............. DI10-49
P1121
Accelerator Pedal Sensor #2 Malfunction ..... DI10-58
P1680
Glow Plug Drive Malfunction -
P1122
Accelerator Pedal Sensor Malfunction
P0113
Intake Air Temperature Circuit Malfunction Short .............................................................. DI10-55
P0112
Intake Air Temperature Circuit Malfunction Open ............................................................. DI10-56
P0110
Intake Air Temperature Circuit Malfunction Source Power Problem .................................. DI10-57
Short to Ground ............................................ DI10-49
(Limp Home Mode) ......................................... DI10-58
P1530
#1 Heater operating circuit - Open ................ DI10-49
P1531
#1 Heater operating circuit - Short ................ DI10-50
P1532
#1 Heater operating circuit - Short to Ground . DI10-50
P1124
Accelerator Pedal Sensor Malfunction - Stuck .. DI10-59
P1534
#2 Heater operating circuit - Open ................ DI10-50
P0122
Accelerator Pedal Sensor #1 Malfunction -
P1535
#2 Heater operating circuit - Short ................. DI10-50
P1536
#2 Heater operating circuit - Short to Ground DI10-50
P1254
Maximum Rail Pressure Control Malfunction

(IMV Fault) .................................................... DI10-51
P1253
P1257
P1259
P0123
Accelerator Pedal Sensor #1 Malfunction Short .............................................................. DI10-59
P0120
Accelerator Pedal Sensor #1 Malfunction Supply Voltage Fault ...................................... DI10-59
P0222
Accelerator Pedal Sensor #2 Malfunction Open .............................................................. DI10-60
P0223
Too Large Transfer Pressure Fuel in

Rail Pressure System ..................................... DI10-52
P1258
Open .............................................................. DI10-59
Too Small Transfer Pressure Fuel in

Rail Pressure System ..................................... DI10-52

(Reduced Torque Mode) ................................ DI10-59
Minimum Rail Pressure Control Malfunction

(IMV Fault) .................................................... DI10-51
P1256
P1123
Accelerator Pedal Sensor #2 Malfunction Short .............................................................. DI10-60
P0220
Too Small High Pressure Fuel in
Accelerator Pedal Sensor #2 Malfunction Supply Voltage Fault ...................................... DI10-60
Rail Pressure System .................................... DI10-53
P0192
Fuel Rail Pressure Sensor Malfunction - Open .. DI10-60
Too Large High Pressure Fuel in
P0193
Fuel Rail Pressure Sensor Malfunction - Short .. DI10-61
Rail Pressure System .................................... DI10-53
P0190
Supply Voltage Fault to
P1191
Pressure Build Up - Too Slow ....................... DI10-54
Fuel Rail Pressure Sensor .............................. DI10-61
P0255
IMV Driver Circuit Malfunction - Open ........... DI10-54
P0191
Fuel Rail Pressure Sensor Signal Fault .......... DI10-61
P0251
IMV Driver Circuit Malfunction - Short ........... DI10-54
P1192
Fuel Rail Pressure Sensor Initial Signal Fault -
P0253
IMV Driver Circuit Malfunction -
Low ............................................................... DI10-62
Short to Ground ............................................ DI10-54
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-28
Fuel Rail Pressure Sensor Initial Signal Fault -
P0671
#1 Glow Plug Fault - Open ............................. DI10-68
High ............................................................... DI10-62
P0672
P1190
Fuel Rail Pressure Sensor Initial Signal Fault .. DI10-63
P0673
P0215
Main Relay Fault - Stuck ................................. DI10-63
P0674
P1500
Vehicle Speed Fault ....................................... DI10-63
P0675
P0642
ECU Supply Voltage 1 Fault - Low (5 V) ........ DI10-63
P1671
#1 Glow Plug Fault - Short (+B) ..................... DI10-69
P0643
ECU Supply Voltage 1 Fault - High (5 V) ........ DI10-64
P1672
#2 Glow Plug Fault - Short (B+) ..................... DI10-69
P0641
ECU Supply Voltage 1 Fault (5 V) ................... DI10-64
P1673
P0652
ECU Supply Voltage 2 Fault - Low (5 V) ........ DI10-64
P1674
P0653
ECU Supply Voltage 2 Fault - High (5 V) ........ DI10-64
P1675
P0651
ECU Supply Voltage 2 Fault (5 V) ................... DI10-64
P0700
TCU Signal Fault ............................................. DI10-70
P0698
ECU Supply Voltage Fault - Low (2.5 V) ........ DI10-65
P1540
Air Conditioner Operating Circuit Fault - Open . DI10-70
P0699
ECU Supply Voltage Fault - High (2.5 V) ........ DI10-65
P1541
Air Conditioner Operating Circuit Fault - Short . DI10-70
P0697
ECU Supply Voltage Fault (2.5 V) ................... DI10-65
P1542
Air Conditioner Operating Circuit Fault -
P0245
Turbo Charger Actuator Circuit Fault - Short .. DI10-65
P0246
Turbo Charger Actuator Circuit Fault -
P1149
Too High Water Level in Fuel Filter ................. DI10-70
Short to B+ ..................................................... DI10-65
P1634
Immobilizer Fault (refer to immobilizer section) .. DI10-70
P0606
ECU Watchdog Fault ...................................... DI10-65
P1635
No response from Immobilizer
P1607
ECU Injector Cut Fault ..................................... DI10-65
P1600
ECU Shut Down Fault ..................................... DI10-66
P1601
ECU Fault ....................................................... DI10-66
P1602
ECU Fault ....................................................... DI10-66
P1631
Immobilizer Fault (refer to immobilizer section) . DI10-71
P1614
ECU C2I/MDP Fault ......................................... DI10-66
P1632
P1615
ECU Fault ....................................................... DI10-66
P1633
P1616
ECU Fault ....................................................... DI10-66
P0633
P1606
ECU Fault ....................................................... DI10-66
P1636
P1620
ECU Fault ....................................................... DI10-66
P1621
ECU Fault ....................................................... DI10-66
P1622
ECU Fault ....................................................... DI10-66
P1603
ECU Fault ....................................................... DI10-67
P1604
ECU Fault ....................................................... DI10-67
P1605
ECU Fault ....................................................... DI10-67
P1148
Accelerometer (Knock Sensor) Learning Fault . DI10-67
P0400
EGR Control Valve Fault ................................. DI10-67
P1235
VGT Operation Fault ...................................... DI10-67
P1608
ECU Fault ....................................................... DI10-67
P0335
No Crank Signals ............................................ DI10-67
P1170
Torque Trim Fault - High ................................. DI10-67
P1676
Glow Plug Communication Fault ..................... DI10-68
P1677
Glow Plug Controller Fault .............................. DI10-68
P1193
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
(refer to immobilizer section) ......................... DI10-70
P1630
Wrong response from Immobilizer

(refer to immobilizer section) ......................... DI10-71
DIAGNOSIS
DI ENG SM - 2004.9
DI10-29
TROUBLE DIAGNOSIS TABLE

DTC
Trouble
Help
P0102
Low HFM Sensor Signal

(Circuit Open)
- HFM sensing values are lower than

minimum sensing values.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- Check the resistance in HFM sensor.

- Check the ECU wiring harness (open
and poor contact).
Check the ECU pin #83 and #84 for
open circuit.
- Actual air mass flow vs. Output
voltages.
-20 Kg/h: 0.47 V
0 Kg/h: 0.99 V
10 Kg/h: 1.2226 ~ 1.2398 V
15 Kg/h: 1.3552 ~ 1.3778 V
30 Kg/h: 1.6783 ~ 1.7146 V
60 Kg/h: 2.1619 ~ 2.2057 V
120 Kg/h: 2.7215 ~ 2.7762 V
250 Kg/h: 3.4388 ~ 3.5037 V
370 Kg/h: 3.8796 ~ 3.9511 V
480 Kg/h: 4.1945 ~ 4.2683 V
640 Kg/h: 4.5667 ~ 4.6469 V
- Replace the ECU if required.
P0103
High HFM Sensor Signal

(Circuit Short)
- HFM sensing values are higher than

maximum sensing values.
- Check the resistance in HFM sensor.
- Check the ECU wiring harness (open
and poor contact).
open circuit.
voltages.
-20 Kg/h: 0.47 V
0 Kg/h: 0.99 V
10 Kg/h: 1.2226 ~ 1.2398 V
15 Kg/h: 1.3552 ~ 1.3778 V
30 Kg/h: 1.6783 ~ 1.7146 V
60 Kg/h: 2.1619 ~ 2.2057 V
120 Kg/h: 2.7215 ~ 2.7762 V
250 Kg/h: 3.4388 ~ 3.5037 V
370 Kg/h: 3.8796 ~ 3.9511 V
480 Kg/h: 4.1945 ~ 4.2683 V
640 Kg/h: 4.5667 ~ 4.6469 V
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-30
DTC
Trouble
P0100
Air Mass Flow (HFM) Malfunction
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
- The external power supply is faulty.

Check the external power supply.
Check the sensor wiring harness
(open, short, poor contact).
voltages.
-20 Kg/h: 0.47 V
0 Kg/h: 0.99 V
10 Kg/h: 1.2226 ~ 1.2398 V
15 Kg/h: 1.3552 ~ 1.3778 V
30 Kg/h: 1.6783 ~ 1.7146 V
60 Kg/h: 2.1619 ~ 2.2057 V
120 Kg/h: 2.7215 ~ 2.7762 V
250 Kg/h: 3.4388 ~ 3.5037 V
370 Kg/h: 3.8796 ~ 3.9511 V
480 Kg/h: 4.1945 ~ 4.2683 V
640 Kg/h: 4.5667 ~ 4.6469 V
P0344
Cam Position Sensor Malfunction (Cam Signal Missing)
- No cam recognition signal (missing

events).
- Check the source voltage of cam position sensor (ECU pin #111) (specified
value: 4.5 ~ 12 V).
- Check the sensor wiring harness for
ECU pin #103 and #104 (open, short,
poor contact).
- Check the cam position sensor.
- Measure the air gap: 0.2 ~ 1.8 mm
P0341
Cam Position Sensor Malfunction (Poor Synchronization)
- Not synchronized with Crank angle

signal.
- Check the source voltage of cam position sensor (specified value: 4.5 ~ 12 V).
ECU pin #103 and #104 (open, short,
poor contact).
- Check the cam position sensor.
P0219
Too Small Clearance of

Crank Angle Sensor
- Crank angle signal faults or clearance

too close.
ECU pin #90 and #82 (open, short, poor
contact).
- Check the resistance of crank angle
sensor: 1090 15 %.
1.3 mm of air gap: outputs 1.0 V at
40 rpm
0.3 mm of air gap: outputs 150 V at
7000 rpm
- Check the teeth condition.
Drive plate (A/T), DMF (M/T)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-31
DTC
Trouble
Help
P0336
Too Large Clearance of

Crank Angle Sensor
- Air gap of crank angle sensor is

abnormal.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

contact).
sensor: 1090 15 %.
40 rpm
7000 rpm
P0372
Crank Angle Sensor Malfunction
- Even though cam position recognition

is normal, no crank angle signal recognition (missing tooth).
contact).
sensor: 1090 15 %.
40 rpm
7000 rpm
P1107
Barometric Sensor Circuit

Short/GND Short
- Out of range about barometric sensor

(short to ground).
- Actual barometric pressure vs. Output
voltages.
15 Kpa: 0 V
35 Kpa: 1.0 V
55 Kpa: 2.0 V
80 Kpa: 3.0 V
100 Kpa: 4.0 V 110 Kpa: 4.5 V

- Replace the ECU.
P1108

Short

(short to B+).
voltages.
15 Kpa: 0 V
35 Kpa: 1.0 V
55 Kpa: 2.0 V
80 Kpa: 3.0 V
100 Kpa: 4.0 V 110 Kpa: 4.5 V

- Replace the ECU.
P1105

Short

(over voltage).
voltages.
15 Kpa: 0 V
35 Kpa: 1.0 V
55 Kpa: 2.0 V
80 Kpa: 3.0 V
100 Kpa: 4.0 V 110 Kpa: 4.5 V

- Replace the ECU.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-32
DTC
P0562
Trouble
Low Battery Voltage
Help
- Malfunction in recognition of system
source voltage (Lower than threshold).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
Less than minimum 8 Volts in 2000

rpm below
Less than 10 Volts in 2000 rpm above.
- Check the battery wiring harness for
ECU pin #3, #4 and #5 (open, short,
poor contact).
- Check the battery main relay and fuse.
- Check the body ground.
- Measure the resistance between body
ground and ECU ground.
Repair the ECU ground if the resistance is high.
P0563
High Battery Voltage

source voltage (Higher than threshold).
More than minimum 16 Volts in 2000

rpm below
poor contact).
- Check the alternator.
P0560
Battery Voltage Malfunction

source voltage (A/D converter faults).
Less than minimum 8 Volts in 2000

rpm below
Less than 10 Volts in 2000 rpm above.
poor contact).
- Check the battery main relay and fuse.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-33
DTC
Trouble
Help
P0109
Low Booster Pressure

Sensor Signal
- Out of signal range about boost pressure sensor at Ignition key-On and Engine Stop (Lower than specified values).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- Check the supply voltage to sensor.

- Actual boost pressure vs. Output
voltages.
Raw Signal Range: 0.545 ~ 2.490 bar
0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
- Check the sensor wiring harness for ECU
pin #99 and #100 (open, poor contact).
- Visually check sensor and replace if
required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
Leakage before turbo system
Vacuum pump malfunction
Waste gate solenoid valve
Turbo charger system defect or malfunction itself
Air inlet restriction
Exhaust system restriction
P0106
High Booster Pressure

Sensor Signal
- Out of signal range about boost pressure sensor at Ignition key-On and Engine Stop (Higher than specified
values).
- Actual boost pressure vs. Output
voltages.
0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
ECU pin #99 and #100 (open, poor
contact).
required.
Turbo charger system defect or
malfunction itself
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-34
DTC
Trouble
Help
P0107
Booster Pressure Sensor

Open/GND Short
- Out of signal range about boost pressure sensor at Engine running condition (Lower than specified values).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

- Actual boost pressure vs. Output voltages
0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
contact).
required.
P0108

Short
- Out of signal range about boost pressure sensor at Engine running condition (Higher than specified values).
Raw Signal Range: 0.545~2.490 bar
0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
contact).
required.
malfunction itself
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-35
DTC
Trouble
Help
P0105

- Out of range of supply voltages about

boost pressure sensor at Ignition keyOn and Engine Stop (Higher than specified values).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
contact).
required.
P1106

Malfunction
- Out of range of supply voltages about

boost pressure sensor at Ignition keyOn and Engine Stop (Higher than specified values).
- Actual boost pressure vs. Output voltages.
0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
contact).
required.
malfunction itself
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-36
DTC
Trouble
Help
P1109

Initial Check Fault
- Implausible signal values or range about

boost pressure sensor at Engine running condition (Higher than specified
values).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

0.4 bar: 0.6120 V
1.4 bar: 2.6520 V
2.4 bar: 4.6920 V
contact).
required.
P0571
Brake Pedal Switch Fault
- The brake pedal switch or light switch

is faulty.
Brake pedal switch: Normal Close
(NC)
Light switch: Normal Open (NO)
When operating the brake switch,
one signal (NO) is sent to auto
cruise and the other (NC) is sent to
brake lamp.
- Check the brake and light switch wiring harness.
- Check the supply voltage to brake and
light switch (12 V).
- Check the brake and light switch for
contact.
- Check the ECU wiring harness for ECU
pin #77 and #58 (short, poor contact).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-37
DTC
P1572
Trouble
Brake Lamp Signal Fault
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- The brake pedal switch or light switch

is faulty.
(NC)
When operating the brake pedal
switch, one signal (NO) is sent to
auto cruise and the other (NC) is
sent to brake lamp.
- Check the brake pedal and light switch
wiring harness.
- Check the supply voltage to brake pedal
and light switch (12 V).
- Check the brake pedal and light switch
for contact.
pin #58 (open, short, poor contact).
P1571
- The brake pedal switch is faulty.

(NC)
When operating the brake pedal
switch, one signal (NO) is sent to
auto cruise and the other (NC) is
sent to brake lamp.
- Check the brake pedal switch wiring
harness.
- Check the supply voltage to brake pedal
switch (12 V).
- Check the brake pedal switch for
contact.
pin #77 (open, short, poor contact).
P1286
Low Resistance for Injector #1 wiring harness
- Out of range about wiring harness resistance for Injector #1.

Low: Less than 0.115 (injector
circuit open)
- Check the injector #1 wiring harness
and electric isolation.
for open circuit.
If the pin in injector #1 is defective,
replace injector #1 and perform C2I
coding, then check again.
If the pin in injector #1 is not
defective, check the ECU wiring
harness.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-38
DTC
Trouble
Help
P1287
High Resistance for Injector #1 wiring harness
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
High: More than 0.728 (injector

circuit short)
for short circuit.
If the trouble still exists after removing the injector connector, replace
injector #1 and perform C2I coding,
then check again.
If the trouble is fixed after removing
the injector connector, check the
wiring harness between ECU and
injector.
P1288

circuit open)
for open circuit.
harness.
P1289

circuit short)
for short circuit.
then check again.
injector.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-39
DTC
Trouble
Help
P1292
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

circuit open)
for open circuit.
harness.
P1293

circuit short)
for short circuit.
then check again.
injector.
P1294

circuit open)
for open circuit.
harness.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-40
DTC
Trouble
Help
P1295
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

circuit short)
for short circuit.
then check again.
injector.
P1290

circuit open)
for open circuit.
harness.
P1291

circuit short)
for short circuit.
then check again.
injector.
P0704
Clutch switch malfunction
- The clutch switch is faulty (Manual

Transmission Only).
- Check the switch wiring harness.
Check the ECU pin #38 for open,
short and poor contact.
- Check the switch supply voltage and
operations.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-41
Trouble
Help
Coolant Temperature Sensor Malfunction
- Implausible values of coolant temperature (If the temperature is below the

limits values after warm up).
DTC
P1115
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- If Fuel temperature is invalid, the previous coolant temperature is retained.

- Actual coolant temp. vs. Resistance
20C: 2449
50C: 826.3
80C: 321.4
100C: 112.9
- Check the wiring harness (open, short
and poor contact).
ECU pin #101 and #102
- Visually check the sensor and replace
if required.
- Check the thermostat, water pump radiator related coolant route (thermostat
stuck).
P0118
Coolant Temperature Sensor Malfunction - Short
- Malfunction in recognition of coolant

temperature
More than maximum values (Circuit
Short)
External power supply malfunction
20C: 2449
50C: 826.3
80C: 321.4
100C: 112.9
- Check the wiring harness (short and
poor contact).
if required.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-42
DTC
Trouble
Help
P0117
Coolant Temperature Sensor Malfunction - Open
- Malfunction in recognition of coolant

temperature
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
Less than minimum values (Circuit

Open)
External power supply malfunction
20C: 2449
50C: 826.3
80C: 321.4
100C: 112.9
- Check the wiring harness (open and
poor contact).
if required.
P0115

- Check if the supply voltage of approx.

12 V is applied.
P0685
Main Relay Malfunction
- The the main relay is unexpectedly

high/low state (ECU is supplied after 3
seconds).
- Relay resistance: 92 9 (at 20C)
- Check the relay wiring harness (open,
short and poor contact).
Check for open and short: ECU pin #9.
- If the forced operation is not available,
replace the ECU.
P1405
EGR Solenoid Valve

Malfunction - Short to
ground
- Out of range about EGR gas: High.

EGR controller circuit: Open or short
to ground
- Check the EGR actuator wiring harness.
- Check the supply voltage to EGR solenoid valve.
- Check the EGR solenoid valve.
- Check the EGR valve for stick.
- Check the resistance of EGR actuator:
15.4 .
- Check the ECU wiring harness for open
and short.
ECU pin #96
P1406
EGR Solenoid Valve

Malfunction - Short to
+Batt
- Out of range about EGR gas: Low.

EGR controller circuit: Short to battery
- Check the EGR solenoid valve.
- Check the EGR valve for stick.
- Check the resistance of EGR actuator:
15.4
and short.
ECU pin #96
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-43
DTC
Trouble
P1480
Condenser Fan #1 Circuit

Malfunction - Open
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- Condenser fan #1: Open

- Check the relay and relay wiring
harness.
and short.
ECU pin #80
- If the forced operation is not available
after replacing the relay, replace the
ECU.
P1481

Malfunction - Short
- Condenser fan #1: Short

harness.
and short.
ECU pin #80
ECU.
P1482

Malfunction - Short to Ground
- Condenser fan #1: Short to ground.

harness.
and short.
ECU pin #80
ECU.
P1526

Malfunction - Open
- Condenser fan #2: Open

harness.
and short.
ECU pin #81
ECU.
P1527

Malfunction - Short
- Condenser fan #2: Short

harness.
and short.
ECU pin #81
ECU.
P1528

Malfunction - Short to Ground
- Condenser fan #2: Short to ground

harness.
and short.
ECU pin #81
ECU.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-44
DTC
Trouble
Help
P0325
Accelerometer #1 (Knock
Sensor) Malfunction
- The signal / noise ratio is too low about

accelerometer # 1.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
- Check the accelerometer wiring harness and tightening torque.

Tightening torque: 20 5 Nm
and short.
ECU pin #45 and #46
- If the trouble still exists even after replacing the accelerometer, replace the
ECU.
P0330
Accelerometer #2 (Knock
Sensor) Malfunction
- The signal / noise ratio is too low about

accelerometer # 1.
- Check the accelerometer wiring harness and tightening torque.
Tightening torque: 20 5 Nm
and short.
ECU pin #44 and #63
- If the trouble still exists even after replacing the accelerometer, replace the
ECU.
P1611
Injector Bank #1 Malfunction - Low Voltage
- Malfunction of injector (#1, #4, #3) circuit (Low): Short to Ground or to

Battery.
- Operating voltage: 6 ~ 18 V
- Check the injector bank #1: Open and
poor contact
- Check if the trouble recurs with the
injectors removed and the ignition key
OFF.
If recurred, check the injector and
ECU wiring harness.
- Check if the trouble recurs while installing the injectors one by one with
the ignition key ON.
If recurred, replace the injector (perform
C2I coding after replacement).
Check the other injectors with same
manner.
- Check the ECU wiring harness.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-45
DTC
Trouble
Help
P1612
Injector Bank #1 Malfunction - High Voltage
- Malfunction of injector (#1, #4, #3) circuit (High): Short to Ground or to Battery.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- Check the injector bank #1: Short and
poor contact
- Check if the trouble recurs with the injectors removed and the ignition key OFF.
ECU wiring harness.
manner.
P1618
Injector Bank #2 Malfunction - Low Voltage
- Malfunction of injector (#2, #5) circuit

(Low): Short to Ground or to Battery.
- Check the injector bank #2: Open and
poor contact
ECU wiring harness.
manner.
P1619
Injector Bank #2 Malfunction - High Voltage
- Malfunction of injector (#2, #5) circuit

(High): Short to Ground or to Battery.
- Check the injector bank #2: Short and
poor contact
ECU wiring harness.
manner.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-46
DTC
Trouble
Help
P0263
Injector #1 Balancing Fault
- Injector #1 cylinder balancing faults

(Injector stuck closed).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
- Check the injector circuit for open.

- Check the glow plug.
- Check the inlet tube for clogging.
- Check the EGR.
- Replace the ECU if required (perform
P0266

- Check the EGR.
P0272

- Check the EGR.
P0275

- Check the EGR.
P0269

- Check the EGR.
P0201
Injector #1 Circuit Open
- Injector #1 circuit malfunction: Open.

If the injector pin is defective, perform C2I coding and check again.
If the injector pin is normal, check
the ECU wiring harness (ECU pin:
#117, #114).
P0202

#118, #121).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-47
DTC
P0204
Trouble
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

#117, #115).
P0205

#118, #120).
P0203

#117, #116).
P1201
Injector #1 Circuit Short
- Injector #1 circuit malfunction: Short.

If the trouble recurs with the injector removed, replace the injector.
Perform C2I coding and check
again.
If the trouble does not recur, check
the wiring harness between the injector and ECU (ECU pin: #117, #114).
P1202

again.
P1204

again.
P1205

again.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-48
DTC
P1203
Trouble
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Help
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

again.
P0182
Fuel temperature sensor Short to Ground
- The sensing values are higher than

specified values for fuel temperature
sensor. (More than maximum sensing
values 140C - Circuit Short)
- Actual fuel temp. vs. Resistance
-40C: 75.780
-20C: 21.873
-10C: 12.462
0C: 7.355
10C: 4.481
20C: 2.812
25C: 2.252
30C: 1.814
40C: 1.199
50C: 0.811
70C: 0.394
90C: 0.206
120C: 0.087
- Recovery values when fuel temperature sensor failure: 95C
- Check the wiring harness for open,
ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.
P0183
Fuel temperature sensor Short to B+
- The sensing values are lower than

specified values for fuel temperature
sensor. (Less than maximum sensing
values - 40C - Circuit Open)
-40C: 75.780
-20C: 21.873
-10C: 12.462
0C: 7.355
10C: 4.481
20C: 2.812
25C: 2.252
30C: 1.814
40C: 1.199
50C: 0.811
70C: 0.394
90C: 0.206
120C: 0.087
ECU pin: #109, #110
ECU if required.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-49
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
DTC
Trouble
Help
P0180
Fuel temperature sensor Malfunction
- The power source circuit is faulty for

fuel temperature sensor. (Fuel temperature sensor is mounted in high
pressure pump)
Delayed
Engine
Stop
Immediately
Engine
Stop

-40C: 75.780
-20C: 21.873
-10C: 12.462
0C: 7.355
10C: 4.481
20C: 2.812
25C: 2.252
30C: 1.814
40C: 1.199
50C: 0.811
70C: 0.394
90C: 0.206
120C: 0.087
ECU pin: #109, #110
ECU if required.
P1678
Glow Plug Drive Malfunction - Open
- Glow plug circuit malfunction: Open.

- Check the glow plug wiring harness
for open.
ECU pin #113
- Check the glow plug relay operations.
- Check the glow plug power supply.
ECU if required.
P1679
Glow Plug Drive Malfunction - Short
- Glow plug circuit malfunction: Short.

for open.
ECU pin #113
ECU if required.
P1680
Glow Plug Drive Malfunction - Short to Ground
- Glow plug circuit malfunction: Short to

ground.
for open.
ECU pin #113
ECU if required.
P1530
#1 Heater operating circuit

- Open
- #1 heater circuit malfunction: Open.

- Check the wiring harness for open.
ECU pin #61
- Check the heater relay operations.
replace the ECU.
ECU if required.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-50
DTC
Trouble
P1531

- Short
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
- #1 heater circuit malfunction: Short.

- Check the wiring harness for short.
ECU pin #61
replace the ECU.
ECU if required.
P1532

- Short to Ground
- #1 heater circuit malfunction: Short to

ground.
ECU pin #61
replace the ECU.
ECU if required.
P1534

- Open
- #2 heater circuit malfunction: Open.

- Check the wiring harness for open.
ECU pin #62
replace the ECU.
ECU if required.
P1535

- Short
- #2 heater circuit malfunction: Short.

ECU pin #62
replace the ECU.
ECU if required.
P1536

- Short to Ground
- #2 heater circuit malfunction: Short to

ground.
ECU pin #62
replace the ECU.
ECU if required.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-51
DTC
Trouble
P1254
Maximum Rail Pressure

Control Malfunction (IMV
Fault)
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
- Rail pressure faults: Too high

- Check the IMV wiring harness.
Check the ECU pin #87 for open and
short.
- Check the high pressure fuel lines, fuel
rails and high pressure pipes for leaks.
- Check the rail pressure sensor.
Supply voltage: 5 0.1 V
Output voltage at 1600 bar: 4.055
0.125 V
Output voltage at atmospheric
pressure: 0.5 0.04 V
- Check the transfer pressure fuel pressure lines.
Check the fuel level in fuel tank.
Check the fuel system for air influx.
Check the fuel filter specification.
- Check the IMV resistance: 5.44
When out of specified value: replace
high pressure pump and IMV
P1253
Minimum Rail Pressure

Control Malfunction (IMV
Fault)
- Rail pressure faults: Too low

short.
- Check the high pressure fuel lines, fuel
rails and high pressure pipes for leaks.
0.125 V
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-52
DTC
Trouble
Help
P1256
Too Small Transfer Pressure Fuel in Rail Pressure

System
- Rail pressure fault: IMV current trim too

high, drift.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

short.
0.125 V
- Check the high pressure fuel system.
Check the fuel rails and high pressure pipes for leaks.
P1257
Too Large Transfer Pressure Fuel in Rail Pressure

System

high, drift.
short.
0.125 V
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-53
DTC
Trouble
Help
P1258
Too Small High Pressure

Fuel in Rail Pressure System

high, drift.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

short.
0.125V
- Check the transfer pressure fuel lines.
P1259
Too Large High Pressure

Fuel in Rail Pressure System

high, drift.
short.
0.125 V
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-54
DTC
Trouble
Help
P1191
Pressure Build Up - Too

Slow
- The pressure build up during cranking

is too slow.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

short.
0.125 V
P0255
IMV Driver Circuit Malfunction - Open
- IMV driver circuit malfunction: Open

Check the ECU pin #87 for open.
- Check the IMV resistance.
P0251
IMV Driver Circuit Malfunction - Short
- IMV driver circuit malfunction: Short

Check the ECU pin #87 for short.
P0253
IMV Driver Circuit Malfunction - Short to Ground
- IMV driver circuit malfunction: Short to

ground
Check the ECU pin #87 for short to
ground.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-55
DTC
Trouble
Help
P0113
Intake Air Temperature Circuit Malfunction - Short
- The intake air temperature sensing

value is lower than maximum value of
150C: Open
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

Actual air temperature vs. Voltages
20C: 2.65
30C: 2.18
50C: 1.40
Recovery values when intake air
temperature sensor failure: 50C
- Check the sensor wiring harness.
Check the source power circuit for
short to ground.
- Check the sensor resistance.
Actual air temperature vs. Resistance
-40C: 39.260
-20C: 13.850
0C: 5.499
20C: 2.420
40C: 1.166
60C: 0.609
80C: 0.340
100C: 0.202
120C: 0.127
open.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-56
DTC
Trouble
Help
P0112
Intake Air Temperature Circuit Malfunction - Open

value is lower than maximum value of
150C: Open
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

20C: 2.65
30C: 2.18
50C: 1.40
short to ground.
-40C: 39.260
-20C: 13.850
0C: 5.499
20C: 2.420
40C: 1.166
60C: 0.609
80C: 0.340
100C: 0.202
120C: 0.127
open.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-57
DTC
Trouble
Help
P0110
Intake Air Temperature Circuit Malfunction - Source

Power Problem

value is lower than minimum value or
higher than maximum value, or the external power to HFM sensor is faulty.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

20C: 2.65
30C: 2.18
50C: 1.40
short to ground.
-40C: 39.260
-20C: 13.850
0C: 5.499
20C: 2.420
40C: 1.166
60C: 0.609
80C: 0.340
100C: 0.202
120C: 0.127
open and short.
P1171
#1 Injector MDP Malfunction
- The #1 injector MDP is faulty.

- C2I coding check
- Check fault code
- No fault condition, vehicle speed 70 KPH
- Coolant temp. 75C above condition try
again
- Replace the injector and perform C2I
coding again.
P1172

- C2I coding check
- Check fault code
again
coding again.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-58
DTC
Trouble
P1174
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

- C2I coding check
- Check fault code
again
coding again.
P1175

- C2I coding check
- Check fault code
again
coding again.
P1173

- C2I coding check
- Check fault code
again
coding again.
P1252
Too High IMV Pressure
- The rail pressure is excessively high.

short.
0.125 V
P1120

#1 Malfunction
- The potentiometer 1 is not plausible

with potentiometer 2.

- Check the wiring harness.
Check the ECU pin #71, 53 and #32,
14 for open and short.
- Check the accelerator pedal module.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-59
DTC
Trouble
Help
P1121

#2 Malfunction
- The potentiometer 1 is not plausible

with potentiometer 2.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

Check the ECU pin #71, 53 and #32,
14 for open and short.
P1122

Malfunction (Limp Home
Mode)
- When triggering limp home mode.

Check the ECU pin #72, 71, 53 and
#57, 32, 14 for open and short.
P1123

Malfunction (Reducde Torque
Mode)
- When triggering reduced torque mode.

Check the ECU pin #72, 71, 53 and
#57, 32, 14 for open and short.
- Replace the ECU if required
P1124

Malfunction - Stuck
- The accelerator pedal sensor is stuck.

- Check the brake switch wiring harness
and operations.
- Check the accelerator pedal operations.
P0122

#1 Malfunction - Open
- Out of range about potentiometer 1 of

pedal sensor: lower than specified
values

Check the circuit for open and short.
Check the ECU pin #71, #53 for open
and poor contact.
- Check the accelerator pedal.
P0123

#1 Malfunction - Short

pedal sensor: higher than specified
values

Check the ECU pin #71, #53 for short
and poor contact.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-60
DTC
Trouble
P0120

#1 Malfunction - Supply
Voltage Fault
Help
- The 5 V supply voltage is faulty.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

and short.
P0222

#2 Malfunction - Open

pedal sensor: lower than specified values

and poor contact.
P0223

#2 Malfunction - Short

pedal sensor: higher than specified values

and poor contact.
P0220

#2 Malfunction - Supply
Voltage Fault
- The 2.5 V supply voltage is faulty.

and short.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-61
DTC
Trouble
Help
P0192
Fuel Rail Pressure Sensor

Malfunction - Open
- The fuel rail pressure sensing values

are lower than specified values.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Minimum sensing values: - 112 bar

(Open)
0.125 V
- Check the sensor and ECU wiring
harness.
and poor contact.
- Check the fuel rail pressure sensor.
P0193

Malfunction - Short
- The fuel rail pressure sensing values

are higher than specified values.
Maximum sensing values: 1,600 bar

(Short)
0.125V
pressure: 0.50.04V
harness.
and poor contact.
P0190
Supply Voltage Fault to Fuel

Rail Pressure Sensor
- The supply voltage to fuel rail pressure sensor is faulty.

0.125V
pressure: 0.50.04V
harness.
and short.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-62
DTC
Trouble
P0191

Signal Fault
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Help
- The rail pressure drop is too high.
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

0.125 V
harness.
and short.
P1192

Initial Signal Fault - Low
- The rail pressure sensor initial values

are lower than specified values with
the ignition ON.
Minimum sensing values: (Open)
90 bar

0.125 V
harness.
and poor contact.
P1193

Initial Signal Fault - High

are higher than specified values with
the ignition ON.
Maximum sensing values: 90 bar

(Short)
0.125 V
harness.
and poor contact.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-63
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
DTC
Trouble
Help
P1190

Initial Signal Fault

are higher or lower than specified values with the ignition ON.
Delayed
Engine
Stop
Immediately
Engine
Stop
Maximum sensing values: 90 bar

(Short)
Minimum sensing values: (Open)
90 bar

0.125 V
harness.
and short.
P0215
Main Relay Fault - Stuck
- The main relay is stuck ; Shut down.

- Resistance of main relay: 92 9
(at 20C)
- Check the main relay wiring harness.
Check the ECU pin #3, 4, 5 for open
and short.
replace the ECU.
- Check the fuse for main relay
P1500
Vehicle Speed Fault
- The vehicle speed signal through CAN

communication is faulty.
- Check the CAN communication line for
open and short.
- Check the ABS/ESP and TCU communication lines.
P0642
ECU Supply Voltage 1 Fault

- Low (5 V)
- Malfunction reference supply voltage

from ECU
Supply voltage: 5 V
- Check the supply voltage to each sensor
Supply voltage (5 V): accelerator
pedal sensor 1, HFM sensor, rail
pressure sensor, booster pressure
sensor, cam sensor
- Check the wiring harnesses.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-64
DTC
Trouble
Help
P0643

- High (5 V)

from ECU
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
Supply voltage: 5 V
sensor, cam sensor
P0641

(5 V)

from ECU
Supply voltage: 5 V
sensor, cam sensor
P0652

- Low (5 V)

from ECU
Supply voltage: 5 V
sensor, cam sensor
P0653

- High (5 V)

from ECU
Supply voltage: 5 V
sensor, cam sensor
P0651

(5 V)

from ECU
Supply voltage: 5 V
sensor, cam sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-65
DTC
Trouble
Help
P0698
ECU Supply Voltage Fault Low (2.5 V)

from ECU
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Supply voltage: 2.5 V

Supply voltage (2.5 V): accelerator
pedal sensor 2
P0699
ECU Supply Voltage Fault High (2.5 V)

from ECU
Supply voltage (2.55 V): accelerator pedal sensor 2
P0697
ECU Supply Voltage Fault

(2.5 V)

from ECU
Supply voltage (2.55 V): accelerator pedal sensor 2
P0245
Turbo Charger Actuator

Circuit Fault - Short
- The waste gate driver circuit is short

to ground or open
- Check the actuator wiring harness.

- Check the solenoid valve.
short.
P0246
Turbo Charger Actuator

Circuit Fault - Short to B+
- The turbo charger actuator power

source circuit is short.
- Check the actuator wiring harness.

- Check the solenoid valve.
- Check the ECU wiring harness for short
and poor contact.
P0606
ECU Watchdog Fault
- The ECU is defective.

- Check the chassis ground wiring
harness.
- Check the ECU.
P1607
ECU Injector Cut Fault

harness.
- Check the ECU.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-66
DTC
P1600
Help
Trouble
ECU Shut Down Fault
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

harness.
- Check the ECU.
P1601
ECU Fault

harness.
- Check the ECU.
P1602
ECU Fault

harness.
- Check the ECU.
P1614
ECU C2I/MDP Fault

harness.
- Check C2I code
- Check the ECU.
P1615
ECU Fault

harness.
- Check the ECU.
P1616
ECU Fault

harness.
- Check the ECU.
P1606
ECU Fault

harness.
- Check the ECU.
P1620
ECU Fault

harness.
- Check the ECU.
P1621
ECU Fault

harness.
- Check the ECU.
P1622
ECU Fault

harness.
- Check the ECU.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-67
P1603
Help
Trouble
DTC
ECU Fault
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
O

harness.
- Check the ECU.
P1604
ECU Fault

harness.
- Check the ECU.
P1605
ECU Fault

harness.
- Check the ECU.
P1148
Accelerometer (Knock
Sensor) Learning Fault
- Check if the MDP is successful.
- Check the accelerometer (knock

sensor) sensor and wiring harness.
P0400
EGR Control Valve Fault
- When the EGR emission is more than

specified value.
The EGR controller circuit is open
or short to ground.
The EGR controller is short to
battery.
- Check if the EGR valve is stuck.
- Check the resistance of EGR valve: 15.
4 .
short.
P1235
VGT Operation Fault
- The boost pressure control is faulty.
- Check the air intake system.

- Check the wiring harness and the ECU
wiring harness.
P1608
ECU Fault

harness.
- Check the ECU.
P0335
No Crank Signals
- Refer to P0372.
P1170
Torque Trim Fault - High
- Refer to P0372.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-68
DTC
Trouble
Help
P1676
Glow Plug Communication

Fault
- The communication between ECU and

glow plug is faulty.
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
- Check the communication line between

ECU and glow plug.
- Check the glow plug wiring harness.
- Check the resistance of glow plug:
below 1 .
- Check the glow plug relay.
ground.
P1677
Glow Plug Controller Fault

glow plug is faulty.
ECU and glow plug.
- Check the glow plug wiring harness.
- Check the resistance of glow plug:
below 1.
- Check the glow plug relay.
ground.
P0671
#1 Glow Plug Fault - Open
- The glow plug circuit is open.

ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 .
- Check each glow plug relay.
P0672

plug: below 1 .
P0673

plug: below 1 .
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-69
DTC
Trouble
P0674
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

plug: below 1.
P0675

plug: below 1 .
P1671
#1 Glow Plug Fault - Short

(B+)
- The glow plug circuit is short.

plug: below 1 .
P1672

(B+)

plug: below 1
P1673

(B+)

plug: below 1
P1674

(B+)

plug: below 1
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-70
DTC
Trouble
P1675

(B+)
Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode

plug: below 1
P0700
TCU Signal Fault

TCU is faulty.
ECU and TCU.
- Check the ECU pin #54, 73 for open
and short.
P1540
Air Conditioner Operating

Circuit Fault - Open
- Check the air conditioner sensors and

wiring harnesses.
- Check the ECU if required.
P1541

Circuit Fault - Short

wiring harnesses.
P1542

Circuit Fault - Short to
Ground

wiring harnesses.
P1149
Too High Water Level in

Fuel Filter
- Drain the water from fuel filter.
P1634
Immobilizer Fault (refer to

immobilizer section)
- No response from immobilizer.

- Perform the immobilizer coding again.
short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna.
P1635
No response from Immobilizer (refer to immobilizer

section)

short.
- Check the immobilizer antenna.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-71
DTC
Trouble
Help
P1630
Wrong response from Immobilizer (refer to immobilizer section)
- The invalid key is inserted or no communication between transponder and immobilizer (no response from transponder).
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop

short.
- Check the immobilizer antenna and
transponder for damage.
P1631

- The immobilizer is not operating.

short.
P1632


short.
P1633

- No key coding.
short.
P0633

- Key memory is not available (permissible

- 5).
short.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Limp
Home
Mode
DI10-72
DTC
Trouble
P1636

Help
Torque
Torque
Reduction Reduction
(max.50%) (max.20%)
Delayed
Engine
Stop
Immediately
Engine
Stop
Limp
Home
Mode
- Severe trouble is not defined.

short.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-73
INDEX OF DTC
HMF sensor Signal Fault (Electric Failure) .......... DI10-77
P0102 ............................................................ DI10-77
P0103 ............................................................ DI10-77
P0100 ............................................................ DI10-77
Brake Lamp Signal Fault ..................................... DI10-93

P1572 ............................................................ DI10-93
P1571 ............................................................ DI10-93
Cam Position Sensor (missing event) .................. DI10-78

P0344 ............................................................ DI10-78
High Wiring Resistance (Injector #1) ................... DI10-94

P1286 ............................................................ DI10-94
P1287 ............................................................ DI10-94
Cam Position Sensor Malfunction

(Poor Synchronization of Crank and Cam) ........... DI10-79
P0341 ............................................................ DI10-79

P1288 ............................................................ DI10-95
P1289 ............................................................ DI10-95
Too Small Clearance of Crank Angle Sensor ........ DI10-80

P0219 ............................................................ DI10-80

P1292 ............................................................ DI10-96
P1293 ............................................................ DI10-96
Too Large Clearance of Crank Angle Sensor ........ DI10-81

P0336 ............................................................ DI10-81
Crank Angle Sensor Malfunction .......................... DI10-82
P0372 ............................................................ DI10-82
Barometric Sensor Malfunction (Out of range, using
strategy of restoring by MAP sensor) .................. DI10-83
P1107 ............................................................ DI10-83
P1108 ............................................................ DI10-83
P1105 ............................................................ DI10-83
Battery Voltage Monitoring Signal Malfunction ..... DI10-84
P0562 ............................................................ DI10-84
P0563 ............................................................ DI10-84
P0560 ............................................................ DI10-84
Booster Pressure Sensor Malfunction
(Out of range with Key ON) ................................. DI10-86
P0109 ............................................................ DI10-86
P0106 ............................................................ DI10-86
(Out of range with Key ON) ................................. DI10-88
P0107 ............................................................ DI10-88
P0108 ............................................................ DI10-88
P0105 ............................................................ DI10-88
P1106 ............................................................ DI10-88
Booster Pressure Malfunction
(Implausible Signal) ............................................. DI10-90
P1109 ............................................................ DI10-90

P1294 ............................................................ DI10-97
P1295 ............................................................ DI10-97
P1290 ............................................................ DI10-98
P1291 ............................................................ DI10-98
Clutch Switch Malfunction ................................... DI10-99
P0704 ............................................................ DI10-99
(Implausible Signal) ........................................... DI10-100
P1115 ........................................................... DI10-100
(Electric Fault) .................................................. DI10-101
P0117 .......................................................... DI10-101
P0118 .......................................................... DI10-101
P0115 .......................................................... DI10-101
Too Fast or Low Main Relay Operation .............. DI10-102
P0685 .......................................................... DI10-102
EGR Actuator Malfunction ................................. DI10-103
P1405 .......................................................... DI10-103
P1406 .......................................................... DI10-103
Condenser Fan Driving Signal Fault (Type 1) ..... DI10-104
P1480 .......................................................... DI10-104
P1481 .......................................................... DI10-104
P1482 .......................................................... DI10-104
Brake Pedal Switch Malfunction .......................... DI10-92

P0571 ............................................................ DI10-92
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-74
Condenser Fan Driving Signal Fault (Type 2) ..... DI10-105
P1526 .......................................................... DI10-105
P1527 .......................................................... DI10-105
P1528 .......................................................... DI10-105
#1 Accelerometer Malfunction
(Idling Signal/Too Small Noise Ratio) ................. DI10-106
P0325 .......................................................... DI10-106
(Idling Signal/Too Small Noise Ratio) ................. DI10-107
P0330 .......................................................... DI10-107
Injector Bank 1 Malfunction
(Short to Ground or B+) ..................................... DI10-108
P1611 .......................................................... DI10-108
P1612 .......................................................... DI10-108
(Short to Ground or B+) ..................................... DI10-110
P1618 .......................................................... DI10-110
P1619 .......................................................... DI10-110
Cylinder Balancing Fault (Injector #1) =
Clogged Air Intake System ................................ DI10-112
P0263 .......................................................... DI10-112
P0266 .......................................................... DI10-113
P0272 .......................................................... DI10-114
P0275 .......................................................... DI10-115
P0269 .......................................................... DI10-116
Open Circuit (Injector #1) ................................... DI10-117
P0201 .......................................................... DI10-117
P0202 .......................................................... DI10-118
P0204 .......................................................... DI10-119
P0205 .......................................................... DI10-120
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

P0203 .......................................................... DI10-121
HSD Circuit Short to LSE (Injector #1) .............. DI10-122
P1201 .......................................................... DI10-122
P1202 .......................................................... DI10-123
P1204 .......................................................... DI10-124
P1205 .......................................................... DI10-125
P1203 .......................................................... DI10-126
Fuel Temperature Sensor Malfunction ................ DI10-127
P0182 .......................................................... DI10-127
P0183 .......................................................... DI10-127
P0180 .......................................................... DI10-127
Glow Plug Malfunction (Driving Signal) .............. DI10-128
P1678 .......................................................... DI10-128
P1679 .......................................................... DI10-128
Heater 1 Malfunction (Driving Signal) ................. DI10-129
P1530 .......................................................... DI10-129
P1531 .......................................................... DI10-129
P1532 .......................................................... DI10-129
Heater 2 Malfunction (Driving Signal) ................. DI10-130
P1534 .......................................................... DI10-130
P1535 .......................................................... DI10-130
P1536 .......................................................... DI10-130
Rail Pressure Control Fault
(Too High Pressure) ........................................... DI10-131
P1254 .......................................................... DI10-131
P1253 .......................................................... DI10-131
(Too High IMV Current Trim, drift) ....................... DI10-133
P1256 .......................................................... DI10-133
P1257 .......................................................... DI10-133
P1258 .......................................................... DI10-133
P1259 .......................................................... DI10-133
(Too Slow Pressure Build Up while Cranking) .... DI10-135
P1191 .......................................................... DI10-135
DIAGNOSIS
DI ENG SM - 2004.9
DI10-75
IMV Operation Fault (Electrical Fault) ................ DI10-137
P0255 .......................................................... DI10-137
P0251 .......................................................... DI10-137
P0253 .......................................................... DI10-137
Intake Air Temperature Sensor Fault
(Electric Fault) .................................................. DI10-138
P0112 .......................................................... DI10-138
P0113 .......................................................... DI10-138
P0110 .......................................................... DI10-138
MDP Fault (Injector #1) ..................................... DI10-139
P1171 .......................................................... DI10-139

(Electrical Fault, Track 2) .................................. DI10-149
P0222 .......................................................... DI10-149
P0223 .......................................................... DI10-149
P0220 .......................................................... DI10-149
Fuel Rail Pressure Sensor Malfunction
(Out of Range, ADC or Vref) .............................. DI10-150
P0192 .......................................................... DI10-150
P0193 .......................................................... DI10-150
P0190 .......................................................... DI10-150
P0191 .......................................................... DI10-150

P1174 .......................................................... DI10-140

(Out of Range when Key ON) ............................ DI10-152
P1192 .......................................................... DI10-152
P1193 .......................................................... DI10-152
P1190 .......................................................... DI10-152

P1175 .......................................................... DI10-140
Main Relay Malfunction - Stuck ......................... DI10-154

P0215 .......................................................... DI10-154

P1173 .......................................................... DI10-141
Vehicle Speed Fault .......................................... DI10-155

P1500 .......................................................... DI10-155
Rail Pressure Fault (Too High) ........................... DI10-142

P1252 .......................................................... DI10-142
5V Supply Voltage 1 Fault ................................. DI10-156

P0642 .......................................................... DI10-156
P0643 .......................................................... DI10-156
P0641 .......................................................... DI10-156

P1172 .......................................................... DI10-139

(Relationship between Track 1 and Track 2) ...... DI10-144
P1120 .......................................................... DI10-144
P1121 .......................................................... DI10-144
(Limp Home Mode Operation) ........................... DI10-145
P1122 .......................................................... DI10-145
5V Supply Voltage 2 Fault ................................. DI10-157

P0652 .......................................................... DI10-157
P0653 .......................................................... DI10-157
P0651 .......................................................... DI10-157

(Torque Reduction Mode Operation) .................. DI10-146
P1123 .......................................................... DI10-146
2.5V Supply Voltage Fault ................................. DI10-158

P0698 .......................................................... DI10-158
P0699 .......................................................... DI10-158
P0697 .......................................................... DI10-158

(Electrical Fault, Pedal Stuck) ......................... DI10-147
P1124 .......................................................... DI10-147
Turbo Charger Actuator Operation Fault (signal) DI10-159

P0245 .......................................................... DI10-159
P0246 .......................................................... DI10-159

(Electrical Fault, Track 1) .................................. DI10-148
P0122 .......................................................... DI10-148
P0123 .......................................................... DI10-148
P0120 .......................................................... DI10-148
ECU Watchdog Fault ........................................ DI10-160

P0606 .......................................................... DI10-160
DIAGNOSIS
DI ENG SM - 2004.9
ECU Watchdog Fault (Injector Cut-off) ............... DI10-151

P1607 .......................................................... DI10-151
ECU Watchdog Fault (Watchdog Trip) .............. DI10-162
P1600 .......................................................... DI10-162
P1601 .......................................................... DI10-162
P1602 .......................................................... DI10-162
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-76
ECU Non-Volatile Memory Fault ........................ DI10-163
P1614 .......................................................... DI10-163
P1615 .......................................................... DI10-163
P1616 .......................................................... DI10-163
P1606 .......................................................... DI10-163
P1620 .......................................................... DI10-163
P1621 .......................................................... DI10-163
P1622 .......................................................... DI10-163
Glow Plug Module Circuit Malfunction - Open .... DI10-173

P0674 .......................................................... DI10-173
P0675 .......................................................... DI10-173
P0671 .......................................................... DI10-173
P0672 .......................................................... DI10-173
P0673 .......................................................... DI10-173
ECU Memory Integration Fault .......................... DI10-164

P1603 .......................................................... DI10-164
P1604 .......................................................... DI10-164
P1605 .......................................................... DI10-164
Glow Plug Module Circuit Malfunction - Short .... DI10-174

P1674 .......................................................... DI10-174
P1675 .......................................................... DI10-174
P1671 .......................................................... DI10-174
P1672 .......................................................... DI10-174
P1673 .......................................................... DI10-174
Accelerometer Learning Fault ............................ DI10-165

P1148 .......................................................... DI10-165
TCU Signal Fault ............................................... DI10-175

P0700 .......................................................... DI10-175
EGR Valve Control Fault .................................... DI10-166

P0400 .......................................................... DI10-166
Air Conditioner Operating Circuit Fault .............. DI10-176

P1540 .......................................................... DI10-176
P1541 .......................................................... DI10-176
P1542 .......................................................... DI10-176
VGT Operation Fault ......................................... DI10-167

P1235 .......................................................... DI10-167
TBD .................................................................. DI10-169
P1608 .......................................................... DI10-169
No Crank Signal ................................................ DI10-170
P0335 .......................................................... DI10-170
High Torque Trim ............................................... DI10-171
P1170 .......................................................... DI10-171
Glow Plug Module Communication Fault ........... DI10-172
P1676 .......................................................... DI10-172
P1677 .......................................................... DI10-172
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Excessive Water in Fuel Filter ........................... DI10-177

P1149 .......................................................... DI10-177
Immobilizer Malfunction ..................................... DI10-178
P1634 .......................................................... DI10-178
P4335 .......................................................... DI10-178
P1630 .......................................................... DI10-178
P1631 .......................................................... DI10-178
P1632 .......................................................... DI10-178
P1633 .......................................................... DI10-178
P0633 .......................................................... DI10-178
P1636 .......................................................... DI10-178
DIAGNOSIS
DI ENG SM - 2004.9
DI10-77
TROUBLE DIAGNOSIS PROCEDURES

HMF sensor Signal Fault (Electric Failure)
Trouble Code and Symptom
Trouble Code
Symptom
P0102
Low Signal
MIL ON
P0103
High Signal
Not available EGR control(Air flow)
P0100
Supply Voltage
Diagnosis Procedures
Read DTC
Fault in sensor supply voltage?
YES
NO
Sensor problem caused by supply voltage.

Locate the problem while disconnecting the
sensor connector one by one. If not a sensor problem, check the sensor supply voltage circuit for open and short.
Check sensor wiring and

connector
Wiring Problem?
NO
YES
Repair or
replace
NO
Wiring Problem?
Check sensor resistance
Resistance Problem?
Check wiring and insulation

YES
NO
YES
Replace
sensor
Replace ECU
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-78
Cam Position Sensor (missing event)

Trouble Code
P0344
Symptom
Check sensor wiring and
connector
NO
Wiring Problem?
YES
Repair or
replace
Check wiring insulation
NO
Wiring Problem?
YES
Repair wiring
Check sensor
NO
Sensor Problem?
YES
Replace
sensor
Check cam installation
NO
Cam Wheel Problem?

Check ECU wiring
YES
Replace cam
wheel
NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
Check if the cam and

flywheel signals are normal
with an oscilloscope
Anmormal Signal?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-79

(Poor Synchronization of Crank and Cam)
Trouble Code
P0341
Symptom
Cam Position Sensor Malfunction - Poor Synchronization
MIL ON
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
NO

NO
Wiring Problem?
Check sensor
Sensor Problem?
YES
YES
Repair wiring
NO
Replace
sensor
Check cam installation
NO
Cam Wheel Problem?
Check ECU wiring
Wiring Problem?
YES
YES
NO
Repair or
replace
Replace ECU
NO
Check if the cam and

flywheel signals are normal
with an oscilloscope
Anmormal Signal?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace cam
wheel
DI10-80
Too Small Clearance of Crank Angle

Sensor
Trouble Code
P0219
Symptom
Too Small Clearance of Crank Angle Sensor
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
NO
Replace APS
wheel
NO
Check ECU wiring

Replace wheel
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
Replace ECU
NO
NO
Check insulation and open

circuit
Repair completed
Wiring Problem?
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
New sensor installed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-81
Too Large Clearance of Crank Angle

Sensor
Trouble Code
P0336
Symptom
Too Large Clearance of Crank Angle Sensor
MIL ON
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
NO
Replace APS
wheel
NO
Check ECU wiring

Replace wheel
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
NO
NO

circuit
Repair completed
Wiring Problem?
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-82
Crank Angle Sensor Malfunction

Trouble Code
P0372
Symptom
Crank Angle Sensor Malfunction 3
MIL ON
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
NO
YES
Replace APS
wheel
NO
Check ECU wiring

Replace wheel
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
NO
YES
Replace ECU
NO

circuit
Repair completed
Wiring Problem?
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-83
Barometric Sensor Malfunction

(Out of range, using strategy of
restoring by MAP sensor)
Trouble Code
P1107
Low Signal
P1108
High Signal
P1105
Supply Voltage
Symptom
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-84
Battery Voltage Monitoring Signal

Malfunction
Trouble Code
Symptom
P0562
Low Signal
Not operatable.
P0563
High Signal
Injector #1 resistance fault. Use estimate resistance level.
P0560
Supply Voltage

Unable EGR control (Air Flow)
Unable RPC trim problem detection
Unable HP leak detection
Unable accelerometer learing strategy
MIL ON
Operating limited rail pressure mode
TBD
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-85
Key ON and check battery
voltage
Battery Problem?
YES
Charge
battery
Charge battery, check wiring
NO
Charge battery, wiring problem
YES
Check battery wiring

NO
Battery Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Check resistance of body

ground and ECU ground
High Resistance
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair ECU
ground
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-86

(Out of range with Key ON)
Trouble Code
P0109
Low
P0106
High
Symptom
Location demand=change the boost control to

O.L. mode at f (boost demand, engine cycling speed)
1. Diagnosis Procedures (Boost Pressure)
Read DTC
Booster Pressure Problem?
YES
Refer to Diagnosis Tree Check sensor(1)
NO
Check air line malfunction:

* VGT/Turbo. * Air filter.
* Vacuum line. * Vacuum pump.
* Solenoid valve open.
* Vane condition.
* Air inlet valve function
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-87
2. Diagnosis Procedure (Check sensor (1))

Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Visually check sensor

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-88

(Out of range with Key ON)
Trouble Code
P0107
Low
P0108
High
P0105
Supply Voltage
P1106
GRAD
Symptom

Read DTC
Booster Pressure Problem?
YES
NO

* Vane condition.
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-89
2. Diagnosis Procedures (check sensor (1))

Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-90
Booster Pressure Malfunction

(Implausible Signal)
Trouble Code
P1109
Symptom

Read DTC

Problem?
YES
NO

* Vane condition.
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-91
2. Diagnosis Procedures (check sensor (1))

Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-92
Brake Pedal Switch Malfunction

Trouble Code
P0571
Symptom
Brake Pedal Switch Malfunction
MIL ON
Unable Cruise Control
Check switch wiring
Wiring Problem?
YES
Repair or
replace
NO
Check ECU wiring

NO
Wiring Problem?
Check 12V switch supply

voltage
YES
Repair or
replace
NO
Source Power Problem?
YES
Check wiring
and fuse
NO
Wiring Problem?
YES
Repair wiring
Check switch operation

NO
Switch Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Replace
switch
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
DI10-93

Trouble Code
Symptom
P1572
MIL ON
P1571
MIL ON
Check switch wiring
Wiring Problem?
YES
Repair or
replace
NO
Check ECU wiring

NO
Wiring Problem?

voltage
YES
Repair or
replace
NO
YES
Check wiring
and fuse
NO
Wiring Problem?
YES

NO
Switch Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
switch
Replace ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-94
High Wiring Resistance (Injector #1)

Trouble Code
Symptom
P1286
Low
Resistance of injector #1 fault. Use estimate resistance level.
P1287
High
MIL ON
Unable Dynamic Leak of Injector #1
Unable Accelerometer Learning Strategy
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
No any other possibility
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-95

Trouble Code
Symptom
P1288
Low
P1289
High
MIL ON
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
Highs Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-96

Trouble Code
Symptom
P1292
Low
P1293
High
MIL ON
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-97

Trouble Code
Symptom
P1294
Low
P1295
High
MIL ON
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-98

Trouble Code
Symptom
P1290
Low
P1291
High
MIL ON
Read DTC
Low Fault?
YES
NO
Refer to
injector circuit
malfunction
(open) tree
Read DTC
High Fault?
NO
YES
Refer to
injector circuit
malfunction
(short) tree
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-99
Clutch Switch Malfunction

Trouble Code
P0704
Symptom
Clutch Switch Malfunction
Check switch wiring
Wiring Problem?
YES
Repair or
replace
NO
Check ECU wiring

NO
Wiring Problem?

voltage
YES
Repair or
replace
NO
YES
Check wiring
and fuse
NO
Wiring Problem?
YES

NO
Switch Contact Problem?
YES
Replace switch
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-100

(Implausible Signal)
Trouble Code
P1115
Symptom
Unable Air Conditioner Operation

Below Limited Temperature of Engine Overheat
Detection
Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-101

(Electric Fault)
Trouble Code
Symptom
P0117
Low
P0118
High

Detection
P0115
Supply Voltage
Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES

NO
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Check ECU wiring
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair or
replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-102
Too Fast or Low Main Relay Operation

Trouble Code
P0685
Symptom
Main Relay Malfunction
Check relay wiring
Wiring Problem?
YES
Repair or
replace
NO
Perform forced operation

and replace relay
NO
Check ECU wiring

Not available forced operation?
Wiring Problem?
YES
Repair or
replace
NO
YES
Replace ECU
NO
Repiar Completed
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair wiring
DIAGNOSIS
DI ENG SM - 2004.9
DI10-103
EGR Actuator Malfunction

Trouble Code
Symptom
P1405
EGR Vacuum Modulator - Short to GND
MIL ON
P1406
EGR Vacuum Modulator - Short to +Batt
Unable EGR Control (Air Flow)
Check actuator wiring
NO
Wiring Problem?
YES
Repair or
replace
Replace actuator
NO
Trouble Continues?
YES
Check resistance of actuator

NO
Resistance Problem?
YES
Replace
actuator
Repiar Completed
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-104
Condenser Fan Driving Signal Fault

(Type 1)
Trouble Code
Symptom
P1480
Open Circuit
P1481
Short Circuit
MIL ON
P1482
Short to Ground

Detection
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO

and replace relay
YES
Replace ECU
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-105
Condenser Fan Driving Signal Fault

(Type 2)
Trouble Code
Symptom
P1526
Open Circuit
P1527
Short Circuit
MIL ON
P1528
Short to Ground

Detection
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
Perform forced drive and

replace relay
YES
Replace ECU
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-106
(Idling Signal/Too Small Noise Ratio)
Trouble Code
P0325
Symptom
#1 Accelerometer (Knock Sensor) Malfunction
MIL ON
Caution: Check the sensing
value of coolant temp., intake
air temp., fuel temp. barometric pressure. Incorrect default
values of theses sensors may
cause wrong diagnosis.
Check accelerometer wiring
and tightening torque, especially shield ground.
NO
Wiring Problem?
YES
Repair or
replace
Replace accelerometer
(knock sensor)
NO
Trouble Continues?
Check ECU wiring
Wiring Problem?
YES
YES
Replace ECU
NO
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair wiring
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-107
(Idling Signal/Too Small Noise Ratio)
Trouble Code
P0330
Symptom
#2 Accelerometer (Knock Sensor) Malfunction
MIL ON
Caution: Check the sensing
value of coolant temp., intake
air temp., fuel temp. barometric pressure. Incorrect default
values of theses sensors
may cause wrong diagnosis.
Check accelerometer wiring
and tightening torque,
especially shield ground.
NO
Wiring Problem?
YES
Repair or
replace
Replace accelerometer
(knock sensor)
NO
Trouble Continues?
Check ECU wiring
Wiring Problem?
YES
YES
NO
Repair or
replace
Repiar Completed
NO
Wiring Problem?
YES
Repair wiring
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-108

(Short to Ground or B+)
Trouble Code
Symptom
P1611
Low Injector Bank 1 Voltage
P1612
High Injector Bank 1 Voltage

MIL ON
Unable Cylinder Balancing
Unable Injector #1 Operation
Unable High Pressure Leak Detection
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-109
1. Fuel Injection Bank 1/2
2. Check Injector Wiring
Injector - short (SC+ or SC-)
Check ECU wiring
Key OFF and check injector

wiring
Wiring Problem?
Injector Wiring Problem?
YES
Repair or
replace
NO
Repair or
replace
NO
Disconnect injector connector and key ON
Trouble Continues?
YES
Wiring Problem?
YES
Refer to check
injector wiring
YES
Repair wiring
NO
Replace ECU
NO
Delete default and key OFF.

Key ON while connecting
injector connectors one by one.
Trouble Recurred?
NO
YES
Replace the
injector - Enter
new injector
C2I into ECU
Repeat same procedures for

all injectors
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-110

(Short to Ground or B+)
Trouble Code
Symptom
P1618
Low Injector Bank 2 Voltage
P1619
High Injector Bank 2 Voltage

MIL ON
Unable High Pressure Leak Detection
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-111
1. Fuel Injection Bank 1/2
2. Check Injector Wiring
Injector - short
Check ECU wiring

wiring
Wiring Problem?
YES
Repair or
replace
NO
Repair or
replace
NO
Disconnect injector connector and key ON
Trouble Continues?
YES
Wiring Problem?
YES
Refer to check
injector wiring
YES
Repair wiring
NO
Replace ECU
NO
Delete default and key OFF.

Key ON while connecting
injector connectors one by one.
Trouble Recurred?
NO
YES
Replace the
injector - Enter
new injector
C2I into ECU
Repeat same procedures for

all injectors
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-112

Clogged Air Intake System
Trouble Code
P0263
Symptom
#1 Cylinder Balancing Fault
MIL ON
Read DTC
NO
Injector Circuit Open?
YES
Circuit Open:
Wiring problem
Check air intake system
NO
Air Intake System Clogged?

Check engine hardware
NO
Engine Hardware Problem?
YES
Repair or
replace
YES
Repair air
intake system
and check
EGR
Replace injector and enter new

injector C2I value into ECU
NO
Check glow plug
Glow Plug Problem?
YES
Repair or
replace
NO
Perform forced valve operation and check it
Valve Problem?
YES
Repair or
replace valve
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-113

Trouble Code
P0266
Symptom
MIL ON
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO
YES

NO
YES
Repair or
replace
Replace injector and enter

new injector C2I into ECU
NO
Check glow plug
Glow Plug Problem?
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair air
intake system
and check
EGR
DI10-114

Trouble Code
P0272
Symptom
MIL ON
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO

NO
YES
Repair or
replace
YES
Repair air
intake system
and check
EGR

NO
Check glow plug
Glow Plug Problem?
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-115

Trouble Code
P0275
Symptom
MIL ON
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO
YES

NO
YES
Repair or
replace

NO
Check glow plug
Glow Plug Problem?
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair air
intake system
and check
EGR
DI10-116

Trouble Code
P0269
Symptom
MIL ON
Read DTC
NO
YES
Circuit Open:
Wiring problem
NO

NO
YES
Repair or
replace
YES
Repair air
intake system
and check
EGR

NO
Check glow plug
Glow Plug Problem?
YES
Repair or
replace
NO
Valve Problem?
YES
Repair or
replace valve
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-117
Open Circuit (Injector #1)

Trouble Code
P0201
Symptom
#1 Injector Circuit - Open
Unable RPC Trim Fault Detection

Unable H/P Leak Detection
wiring
NO
Wiring Problem?
YES
Repair or
replace
Check ECU wiring
NO
Wiring Problem?
YES

NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
If the wiring is normal,

disconnect the injector
connectors and check the
resistance (difficult to check
injector resistance)
NO
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
injector
and enter new
injector C2I
value into ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-118

Trouble Code
P0202
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
Check ECU wiring
NO
Wiring Problem?
YES
Repair or
replace

NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO

NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Replace
injector
and enter new
injector C2I
value into ECU
DIAGNOSIS
DI ENG SM - 2004.9
DI10-119

Trouble Code
P0204
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
Check ECU wiring
NO
Wiring Problem?
YES

NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO

NO
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
injector
and enter new
injector C2I
value into ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-120

Trouble Code
P0205
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
Check ECU wiring
NO
Wiring Problem?
YES
Repair or
replace

NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO

NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Replace
injector
and enter new
injector C2I
value into ECU
DIAGNOSIS
DI ENG SM - 2004.9
DI10-121

Trouble Code
P0203
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
Check ECU wiring
NO
Wiring Problem?
YES

NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO

NO
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
injector
and enter new
injector C2I
value into ECU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-122
HSD Circuit Short to LSE (Injector #1)

Trouble Code
P1201
Symptom
#1 Injector Circuit - Short

wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
Disconnect injector connector

NO
Same Trouble Continues?
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU
Shorted injector circuit.

Check wiring from injector tip
to ECU.
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-123

Trouble Code
P1202
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES

NO
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU

to ECU.
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-124

Trouble Code
P1204
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU

to ECU.
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-125

Trouble Code
P1205
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES

NO
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU

to ECU.
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-126

Trouble Code
P1203
Symptom

wiring
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
YES
NO
Replace
injector
and enter new
injector C2I
value into ECU
Replace ECU

to ECU.
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-127
Fuel Temperature Sensor Malfunction

Trouble Code
P0182
Low
P0183
High
P0180
Supply Voltage
Symptom
Read DTC
YES
NO
Sensor problem caused by supply voltage

to sensor. Locate the problem while disconnecting the sensor connectors one by
one. If not sensor problem, check sensor
supply voltage circuit for open and short.
Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES

NO
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-128
Glow Plug Malfunction (Driving Signal)

Trouble Code
Symptom
P1678
Open Circuit
MIL ON
P1679
Short Circuit
Glow Plug Indicator ON
P1680
Short to Ground
Check glow plug box wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
Replace glow plug box
Trouble Continues?
YES
Replace ECU
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-129
Heater 1 Malfunction (Driving Signal)

Trouble Code
P1530
Open Circuit
P1531
Short to +Batt
P1532
Short to Ground
Symptom
Unable Heater Operation
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO

and replace relay
YES
Replace ECU
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-130
Heater 2 Malfunction (Driving Signal)

Trouble Code
P1534
Open Circuit
P1535
Short to +Batt
P1536
Short to Ground
Symptom
Unable Heater Operation
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO

and replace relay
YES
Replace ECU
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-131

(Too High Pressure)
Trouble Code
Symptom
P1254
Maximum Value
Unable Accelerometer Decoding
P1253
Minimum Value
MIL ON
1. Rail Pressure Control
Read DTC
Rail preaaure sensor or IMV

Related DTC?
YES
Refer to IMV
diagnosis
NO
Check transfer fuel system
YES
YES
Repair or
replace
Check high pressure fuel

system
H/P Fuel System Problem?
YES
NO
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
Repair or
replace
NO
NO

Problem?
Transfer Fuel System

Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-132
2. Transfer Fuel System
3. High Pressyre Fuel System
Check fuel level
Fuel Exhausted?

system
YES
Add fuel
Cause Found?
YES
Add fuel
NO
NO
Visually check transfer fuel

system (fuel leaks, installation)

Problem?
HP fuel system is normal
YES
Repair or
replace
NO
Check if the air in transfer

fuel system is too much
Excessive Air in Transfer

Fuel System?
YES
NO
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
Check fuel filter specification
Different Specification?
YES
Replace filter
with new one
NO
Transfer fuel system is normal
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-133

(Too High IMV Current Trim, drift)
Trouble Code
Symptom
P1256
Small Delivery of Transfer Fuel
P1257
Large Delivery of Transfer Fuel
MIL ON
P1258
Small Delivery of High Pressure Fuel
P1259
Large Delivery of High Pressure Fuel

1. Diagnosis Procedures (Rail Pressure Control)
Read DTC

Related DTC?
YES
Refer to IMV
diagnosis
NO
YES
YES
Repair or
replace

system
YES
NO
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
Repair or
replace
NO
NO

Problem?

Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-134
2. Diagnosis Procedures (Transfer Fuel System)

Check fuel level
NO
Fuel Exhausted?
YES
Add fuel
NO

Problem?
YES
Replace filter
with new one
NO
YES
Repair or
replace
Repiar Completed
NO

fuel system is too much

Fuel System?
YES
NO
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
3. Diagnosis Procedures (High Pressure Fuel System)

Cause Found?
YES
Repair or
replace
NO
H/P Fuel System - Normal

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-135
Rail Pressure Control Fault (Too Slow

Pressure Build Up while Cranking)
Trouble Code
P1191
Symptom
Rail Pressure Build Up - Too Slow

Limited Rail Pressure Mode Operation
Read DTC

Related DTC?
YES
Refer to IMV
diagnosis
NO
YES
YES
Repair or
replace

system
YES
NO
Replace ECU
DIAGNOSIS
DI ENG SM - 2004.9
Repair or
replace
NO
NO

Problem?

Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-136

Check fuel level
NO
Fuel Exhausted?
YES
Add fuel
NO

Problem?
YES
Replace filter
with new one
NO
YES
Repair or
replace
Transfer fuel system is normal
NO

fuel system is too much (with
a low pressure tester)

Fuel System?
YES
NO
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
3. Diagnosis Procedures (High Pressyre Fuel System)

Cause Found?
YES
Repair or
replace
NO

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-137
IMV Operation Fault (Electrical Fault)

Trouble Code
Symptom
P0255
Open Circuit
P0251
Short Circuit
Delayed Engine Stop
P0253
Short to Ground

Check IMV wiring
NO
Wiring Problem?
YES
Check resistance of IMV

Repair or
replace
NO
Resistance Problem?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace H/P
pump and IMV
DI10-138
Intake Air Temperature Sensor Fault

(Electric Fault)
Trouble Code
P0112
High
P0113
Low
P0110
Supply Voltage
Symptom
MIL ON
Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
Resistance Problem?
YES
Replace
sensor
Replace ECU
NO
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-139
MDP Fault (Injector #1)

Trouble Code
P1171
#1 Injector MDP Fault
Symptom
MIL ON
Unable Pilot and Post Injection
Torque Limit For Injector Drift
Enter the injector data into
ECU after replacing injector

Trouble Code
P1172
Symptom
MIL ON
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-140

Trouble Code
P1174
Symptom
MIL ON

Trouble Code
P1175
Symptom
MIL ON
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-141

Trouble Code
P1173
Symptom
MIL ON
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-142
Rail Pressure Fault (Too High)

Trouble Code
P1252
Symptom
Too High IMV Pressure
Read DTC
NO

Related DTC?
YES
Refer to
IMV diagnosis
NO

Problem?

system
YES
Repair or
replace
YES
Repair or
replace
NO
Replace ECU
NO

Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-143

Check fuel level
NO
Fuel Exhausted?
YES
Add fuel
NO

Problem?
YES
NO
YES
Repair or
replace
Repiar Completed
NO

fuel system is too much (with
a low pressure tester)

Fuel System?
YES
Install a
container to
H/P pump
venturi.
Remove
venturi return
lines. Fill fuel
with hand
pump.
3. Diagnosis Procedures (High Pressyre Fuel System)

Cause Found?
YES
Repair or
replace
NO

DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace filter
with new one
DI10-144

(Relationship between Track 1 and Track 2)
Trouble Code
Symptom
P1120
Accelerator Pedal Sensor 1 Malfunction
P1121
Accelerator Pedal Sensor 2 Malfunction
Torque Reduction Mode Operation
Read DTC
YES
NO
Sensor Wiring Problem?
Wiring Problem?
YES
YES

Replace
sensor
Repair or
replace
NO
NO
Wiring Problem?
YES
Repair wiring

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-145

(Limp Home Mode Operation)
Trouble Code
P1122
Symptom
Accelerator Pedal Sensor Malfunction (Limp

Home Mode)
MIL ON
Limp Home Mode Operation
Read DTC
YES
NO
Check sensor wiring
Wiring Problem?
YES
YES

Replace
sensor
Repair or
replace
NO
NO
Wiring Problem?
YES
Repair wiring

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-146

(Torque Reduction Mode Operation)
Trouble Code
P1123
Symptom
Accelerator Pedal Sensor Malfunction (Torque

Mode)
MIL ON
Read DTC
YES
NO
Check sensor wiring
Wiring Problem?
YES
YES

Replace
sensor
Repair or
replace
NO
NO
Wiring Problem?
YES
Repair wiring

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-147

(Electrical Fault, Pedal Stuck)
Trouble Code
P1124
Symptom
Accelerator Pedal Sensor Malfunction - Stuck

Read DTC
NO
Brake switch malfunction
YES
NO
Repair or
replace brake
switch.
Check ECU wiring
Wiring Problem?
Check if accelerator pedal is
normal
Accelerator Pedal Stuck?
YES
Repair or
replace
NO
YES
NO

Replace
accelerator
pedal
Wiring Problem?
Check if accelerator pedal

signal is correct with scan tool
YES
Repair wiring
NO
Replace brake switch

Signal Problem?
YES
Repair or
replace
Trouble Continues?
NO
NO
Check brake wiring connection
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
YES
Repair or
replace
Repiar Completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-148

(Electrical Fault, Track 1)
Trouble Code
Symptom
P0122
Low
MIL ON
P0123
High
P0120
Supply Voltage
Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-149

(Electrical Fault, Track 2)
Trouble Code
Symptom
P0222
Low
MIL ON
P0223
High
P0220
Supply Voltage
Read DTC
YES
NO

Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring

NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repiar Completed
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-150

(Out of Range, ADC or Vref)
Trouble Code
Symptom
P0192
Low
P0193
High
P0190
Supply Voltage
P0191
Excessive Pressure Drop

Fully Forced Open IMV
Unable High Rail Pressure Detection
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-151
Read DTC
Sensor Voltage Fault?
YES
NO

Check sensor wiring

(Check sensor output)
Wiring Problem?
NO
YES
Repair or
replace
NO
Trouble Continues?
Check ECU wiring
Wiring Problem?
Replace rail and sensor

YES
NO
YES
Repair or
replace
Check fuel system
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-152

(Out of Range when Key ON)
Trouble Code
Symptom
P1192
Low
P1193
High
P1190
Supply Voltage

Fully Forced Open IMV
Unable High Rail Pressure Detection
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-153
Check sensor wiring
NO
Wiring Problem?
YES
Repair or
replace
Reinstall connect and wiring
NO
Trouble Continues?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repair completed
NO
Check resistance of wiring
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair wiring
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace rail
and sensor
DI10-154
Main Relay Malfunction - Stuck

Trouble Code
P0215
Symptom
Main Relay Malfunction- Stuck
MIL ON
Check relay wiring
NO
Wiring Problem?
YES
Repair or
replace

and replace relay
NO
Not available forced

operation?
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
YES
Replace ECU
NO
Repair completed
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair wiring
DIAGNOSIS
DI ENG SM - 2004.9
DI10-155
Vehicle Speed Fault

Trouble Code
P1500
Symptom
Vehicle Speed Fault
Check vehicle conditions
NO
Automatic Transmission
Equipped?
YES
NO
Recognize
vehicle speed
through CAN.
Check CAN
and
transmission.
Check sensor and wiring
Wiring Problem?
Check gear box target
Gear Box Target Problem?
YES
NO
YES
Install new target

Repair or
replace
NO
Trouble Continues?
YES
Check ECU wiring

NO
Wiring Problem?
YES
Repair or
replace
Repair completed
NO
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
Replace gear
box target
YES
Repair or
replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-156
5V Supply Voltage 1 Fault

Trouble Code
P0642
Low
P0643
High
P0641
Supply Voltage
Symptom
Supply Voltage 1 (5V):
Accelerator Pedal Sensor 1
Supply Voltage 2 (5V): HFM
sensor, Rail pressure
sensor, Boost pressure
sensor and Cam sensor
Supply Voltage (2.5 V): Accelerator Pedal Sensor 2
Read DTC
All DTCs for sensors

connected to sensor supply
voltage?
YES
Sensor problem caused by supply voltage to

sensor. Locate the problem while disconnecting the sensor one by one. If not sensor
problem, check wiring.
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-157
5V Supply Voltage 2 Fault

Trouble Code
P0652
Low
P0653
High
P0651
Supply Voltage
Symptom
Supply Voltage 1 (5 V):
Supply Voltage 2 (5 V): HFM
Supply Voltage (2.5 V): Accelerator Pedal Sensor 2
Read DTC

voltage?
YES

to sensor. Locate the problem while disconnecting the sensor one by one. If not
sensor problem, check wiring.
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-158
2.5V Supply Voltage Fault

Trouble Code
P0698
Low
P0699
High
P0697
Supply Voltage
Symptom
Supply Voltage 1 (5 V):
Supply Voltage 2 (5 V): HFM
Supply Voltage (2.5 V):
Read DTC

voltage?
YES

to sensor. Locate the problem while disconnecting the sensor one by one. If not
sensor problem, check wiring.
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-159
Turbo Charger Actuator Operation Fault

(signal)
Trouble Code
Symptom
P0245
Short to GND
P0246
Short Circuit to B+
Unable VGT Operation
Check actuator wiring
NO
Wiring Problem?
YES
Repair or
replace
Replace actuator
NO
Trouble Continues?
YES
Check resistance of actuator

NO
Resistance Problem?
YES
Replace
actuator
Repair completed
NO
Check EUC wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-160
ECU Watchdog Fault

Trouble Code
P0606
Symptom
ECU Watchdog Fault
Read DTC
ECU Related DTC?
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-161
ECU Watchdog Fault (Injector Cut-off)

Trouble Code
P1607
Symptom
ECU Injector Cut-off
Read DTC
ECU Related DTC?
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-162
ECU Watchdog Fault (Watchdog Trip)

Trouble Code
P1600
Trip TPU Write Fault
P1601
Trip Shut Dowm Write Fault
P1602
Trip Noise Write Fault
Symptom
Read DTC
ECU Related DTC?
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-163
ECU Non-Volatile Memory Fault

Trouble Code
Symptom
P1614
MDP
MIL ON/Limp Home Mode Operation
P1615
Tele-Coding
P1616
Watchdog
P1606
CAN
P1620
ECU Malfunction
P1621
ECU Malfunction
P1622
ECU Malfunction
MIL ON
Read DTC
ECU Related DTC?
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-164
ECU Memory Integration Fault

Trouble Code
Symptom
P1603
Code Integrity
Immediately Engine Stop
P1604
Code Integrity
P1605
Code Integrity
Read DTC
ECU Related DTC?
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-165
Accelerometer Learning Fault

Trouble Code
P1148
Symptom
Accelerometer (Knock Sensor) Learning Fault
Torque Reduction Operation

Read DTC
Knock Sensor Related DTC?
NO
YES
Refer to
Accelerometer (Knock
Sensor)
Diagnosis
Vehicl driving conditions are

not satisfy with MDP learning
requirements
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-166
EGR Valve Control Fault

Trouble Code
P0400
Symptom
EGR Valve Control Fault
Read DTC
EGR valve and HFM sensor

related DTC?
YES
Check
sensors and
EGR system
NO
Check vacuum modulator/

turbo charger boost modulator and vacuum lines for leak
and installation
Repair completed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-167
VGT Operation Fault

Trouble Code
P1235
Symptom
VGT Operation Fault

Location demand=change the boost control to O.L.
mode at f (boost demand, engine cycling speed)
1. Diagnosis Procedures(Boost Pressure)
Read DTC
Boost Pressure Problem?
NO
YES
Refer to
Diagnosis
Tree Check
sensor(1)

* Vane condition.
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-168
2. Diagnosis Procedures(Check sensor (1))

Read DTC
Sensor Supply Voltage

Problem?
YES

NO
Check sensor wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Check ECU wiring

NO
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
Check fuel system
DIAGNOSIS
DI ENG SM - 2004.9
DI10-169
TBD
Trouble Code
P1608
Symptom
ECU Malfunction
Read DTC
ECU Related DTC?
YES
Check body
ground wiring
NO
Check wiring
Trouble Continues?
YES
Replace ECU
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-170
No Crank Signal

Trouble Code
P0335
Symptom
No Crank Signal
MIL ON
Check sensor wiring
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
NO
Replace APS
wheel
NO
Check ECU wiring

Install new wheel
Wiring Problem?
YES
Repair or
replace
Trouble Continues?
YES
Replace ECU
NO
NO
Check wiring for open and

short
Wiring Problem?
Repair completed
YES
Repair wiring
NO
Trouble Continues?
YES
Replace VR
sensor
NO
Install new sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-171
High Torque Trim

Trouble Code
P1170
Symptom
High Torque Trim
MIL ON
Read DTC
IMV Related DTC?
YES
Refer to IMV
diagnosis
NO
Read DTC
NO

Problem?
YES
Repair or
replace

system
NO
High pressure fuel system

Problem?
Check transfer pressure fuel

system
YES
NO
Transfer pressure fuel

system Problem?
YES
Repair or
replace
Replace ECU
* Refer to Check High and Transfer pressure system.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair or
replace
DI10-172
Glow Plug Module Communication Fault

Trouble Code
P1676
Communication
P1677
Controller
Symptom
Read DTC
NO
Poor Glow Plug

Communication?
YES
NO
Communication problem
between ECU
and glow plug
box. Check
related wirings.
Wiring Problem?
YES
Repair wiring

NO
Wiring Problem?
YES
Repair or
replace
NO
Trouble Continues?
Check glow plug and wiring
(Resistance: below 1 )
Problems?
YES
Replace ECU
NO
YES
NO
Repair or
replace glow
plug
Repair completed
Check ECU wiring
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-173
Glow Plug Module Circuit Malfunction Open

Trouble Code
P0671
Glow Plug #1
P0672
Glow Plug #2
P0673
Glow Plug #3
P0674
Glow Plug #4
P0675
Glow Plug #5
Symptom
Read DTC
NO
Poor Glow Plug

Communication?
YES
NO
between ECU
and glow plug
box. Check
related wirings.
Wiring Problem?
YES
Repair wiring

NO
Wiring Problem?
YES
Repair or
replace

YES
NO
Trouble Continues?
NO
Repair completed
Problems?
YES
NO
Repair or
replace glow
plug
Check ECU wiring
Wiring Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Repair or
replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Replace ECU
DI10-174
Glow Plug Module Circuit Malfunction Short (B+)

Trouble Code
P1671
Glow Plug #1
P1672
Glow Plug #2
P1673
Glow Plug #3
P1674
Glow Plug #4
P1675
Glow Plug #5
Symptom
Read DTC
NO
Poor Glow Plug

Communication?
YES
NO
between ECU
and glow plug
box. Check
related wirings.
Wiring Problem?
YES
Repair wiring

NO
Wiring Problem?
YES
Repair or
replace

YES
NO
Trouble Continues?
Replace ECU
NO
Repair completed
Problems?
YES
NO
Repair or
replace glow
plug
Check ECU wiring
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
DIAGNOSIS
DI ENG SM - 2004.9
DI10-175
TCU Signal Fault

Trouble Code
P0700
Symptom
TCU Signal Fault
Check ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair wiring
NO
Check CAN communication

(between High and Low: 120 )
continues
YES
Repair or
replace
(Replace TCU)
NO
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-176
Air Conditioner Operating Circuit Fault

Trouble Code
Symptom
P1540
Open Circuit
Unable A/C Operation
P1541
Short to +Batt
P1542
Short to Ground
Check vehicle condition
(above fault is related to A/C
system)
Switch without sensor?
NO
YES

N/A
NO
Wiring Problem?
Check sensor connection
Wiring Problem?
YES
Repair wiring
NO
YES
Repair or
replace
Check A/C circuit and

compressor
NO
A/C Problem?
YES
Check sensor
Repair or
replace
NO
Sensor Problem?
YES
Replace
sensor
Replace sensor
NO
Trouble Continues?
YES
Replace ECU
Check ECU wiring

NO
Wiring Problem?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
YES
Repair or
replace
Repair completed
DIAGNOSIS
DI ENG SM - 2004.9
DI10-177
Excessive Water in Fuel Filter

Trouble Code
P1149
Symptom
Excessive Water in Fuel Filter
Water Separator Warning Light ON

Remove fuel filter
NO
Water in fuel filter?
YES
Repair
completed
Check ECU wiring
NO
Wiring Problem?
Check water detection sensor
YES
Repair or
replace
NO
Wiring Problem?
YES
Repair or
replace
NO
Wiring Problem?
Check water detection

sensor wiring
YES
NO
Wiring Problem?
YES
Repair or
replace
Replace ECU
NO
Check resistance of water

detection sensor
Resistance Problem?
DIAGNOSIS
DI ENG SM - 2004.9
YES
Replace
coolant
temperature
sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Repair wiring
DI10-178
Immobilizer Malfunction
Trouble Code
P1634
Symptom
Immobilizer Malfunction
MIL ON
Immobilizer Warning Light ON
P4335
P1630
P1631
P1632
P1633
P0633
P1636
Check immobilizer unit
and ECU wiring
Wiring Problem?
YES
Repair or
replace
NO
Perform immobilizer coding

again
YES
Repair
completed
NO
Repair or replace immobilizer unit and related devices
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-179
FUEL SYSTEM DIAGNOSIS
FUEL SYSTEM DIAGNOSIS ................................... DI10-180

Overview ............................................................. DI10-180
Fuel pressure system ......................................... DI10-181
Fuel system pressure test .................................. DI10-184
Fuel system check process ................................ DI10-186
PRESSURE LEAKAGE TEST WITH SCAN-100 ...... DI10-195
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-180
FUEL SYSTEM DIAGNOSIS

OVERVIEW
When the Diagnostic Trouble Code (DTC) is detected through scan tool, its necessary to check the transfer and high
pressure fuel lines in fuel system before replacing the components.
If the trouble continues even after the trouble has been fixed with scan tool, must perform the fuel pressure test.
Below schematic diagram shows the specifications of pressure, flow mass and temperature in fuel system.
Transfer fuel
pressure regulator
Pressure limit valve

(High pressure line)
IMV
High pressure
pump
Transfer pump
Supply
valve
Suction
valve
Below 2 bar
Below -0.3 bar
Venturi
Common rail
Up to
1050 bar
-0.6 ~ 0.1 bar

-0.6 ~ 0.1 bar
0.05 ~ 0.1 bar

Priming pump
Injectors
Fuel filter
High pressure fuel

supply line
Transfer fuel supply line
Fuel tank
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Return line
DIAGNOSIS
DI ENG SM - 2004.9
DI10-181
FUEL PRESSURE SYSTEM
Pressure/Volume Consumption in System
Pressure/Volume Displacement from Pump
Conservation of fuel pressure/

volume (rail) for proper system
operation
Pump capacity for

supplying the required
Injector back
leak volume
target pressure/volume
Fuel injection
volume
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-182
Example of Too Much Injector Back leak
Increased injector back leak volume
Pressure/volume loss
Injector back
leak volume
Pump capacity
Fuel injection
volume
Pressure/volume
consumption
Pressure/volume
build up
Too Much Injector Back leak

When the injector cannot be sealed due to entering the foreign materials
Example:
Foreign materials in fuel
Burnt out or worn high pressure pump
Mechanical damage in inside of injector
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-183
Example of Pressure/Volume Loss in Pump
Decreased pressure/volume from

pump
Pressure/volume loss
Injector back
leak volume
Pump capacity
Fuel injection
volume
Pressure/volume
consumption
Pressure/volume
build up
Pressure/Volume Loss in High Pressure Pump

When the required target pressure/volume cannot be delivered due to fuel supply line or pump damage
Example:
Air in fuel supply line
Excessive vacuum pressure in fuel supply line (-300 mbar)
Burnt out or mechanically damaged pump
Supply fuel with increased temperature ( > 65C)
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-184
FUEL SYSTEM PRESSURE TEST

Test Tool Kit
For High Pressure Line
For Transfer Line
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-185
Prerequisite
1. Check the connections in fuel supply lines.
2. Check the fuel level in fuel tank.
3. Check if the air exists in fuel supply lines (air bubbles in fuel supply lines or fuel with air bubbles).
4. Check the fuel supply lines for leaks (transfer and high pressure).
5. Check if the specified fuel is used.
6. Check the fuel filter for contamination and abnormality.
Fuel System Test Process

Determine DTC
No
No
DTC Detected?
High pressure fuel

related problem
Check and repair

transfer and H/P fuel
system
Yes
Fuel system
related DTC:
P1252, P1253,
P1254...P0251
no
Check fuel filter and H/P

fuel system
Diagnose and repair

according to the detected DTC
Notice
If more than one DTC have been detected, check the wiring
harness for open or short first.
Check the transfer fuel system and fuel filter before
proceeding the high pressure fuel system check in next page.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-186
FUEL SYSTEM CHECK PROCESS

Initial Check
Transfer fuel system (air in system), specified fuel used
Fuel leaks, fuel filter
Diagnostic Trouble Code
Wiring harness
Abnormal noise from injector
No Abnormality
in Initial Check?
No
Check and repair
Yes
Check fuel rail pressure (refer to 4-1)

When cranking engine for 5 seconds
after disconnecting IMV connector, is
the rail pressure over 1,050 bar?
Check transfer fuel system (refer to 4-2)
Yes
Install the transparent tube between fuel

filter and priming pump. Check the transfer fuel system for clogged or air bubbles.
Check if the vacuum pressure is proper.
No
* Thoroughly clean the components

before installation
Check the injector

back leak volume
Method 1
Method 2
Static Test for Injector Back leak Volume

(refer to 4-3)
Dynamic Test for Injector Back leak Volume (refer to 4-4)

(with engine running)
(with engine cranking but not running)

Place an empty plastic container under the return of
injector:
1. Warm up engine (coolant temp.: over 60C), place an

empty plastic container under the return of injector, and
start engine.
Remove IMV and injector connectors, crank for 5

seconds, and check the injector back leak volume.
The fuel length in tube should be over 20 cm.
2. Run the engine for 30 seconds at idle speed, perform :

fuel system pressure leakage test with Scan-i, and
check the fuel level in container. It should be over 38 ml.
High Pressure Pump Test (refer to 4-5)

No
Yes
Install the closed rail into high pressure

pump at outlet port. Remove IMV connector
and crank engine for 5 seconds. Is the pressure over 1,050 bar?
No
Yes
Replace the injector
Replace the injector
Enter new injector C2I data into ECU

after replacing the injector
Enter new injector C2I data into ECU

after replacing the injector
Perform the initial check again.
Yes
No
Replace high pressure pump

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-187
4-1. High Pressure System Pressure Test

Fuel Rail Pressure Test
1. Disconnect the fuel rail pressure sensor connector and
IMV connector.
2. Install the pressure tester in tool kit to the fuel rail

pressure sensor connector.
3. Crank the engine for 5 seconds (twice).

- Read the maximum pressure displayed on the tester.
- If the maximum pressure is below 1,050 bar, refer to
Fuel System Check Process section.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-188
How To Use Pressure Tester

1. Check if the TEST? is displayed on the display when
pressing the
button.
2. The maximum pressure will be displayed when pressing

the button while cranking the engine (around 4 seconds
elapsed from 5 seconds).
Note
The fuel rail pressure can be measured through the scan

tool.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-189
4-2. Transfer Fuel System Test

Test Procedures
1. All wiring harnesses, connectors and fuel lines should
be installed properly and the engine should be ready to
start.
2. Prepare the special tools for transfer fuel system test
and thoroughly clean the system.
3. Disconnect the key connector for connecting the priming pump to fuel filter and install both connectors of the
special tool to the fuel pump and the priming pump hoses.
4. Start the engine and visually check the transfer line for clogged and air bubbles while running the engine at idle
speed.
5. If the fuel flows are not smooth or air bubbles are found in fuel lines, locate the leaking area and correct it.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-190
4-3. Static Test for Injector Back leak Volume

1. Remove the injector return hose and seal the openings with screw type caps (included in tool kit).
2. Install the hoses from back leak test containers to return

nipples of injector.
3. Disconnect the IMV connector in H/P pump and the fuel

pressure sensor connector.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
DI10-191
4. Crank the engine twice with 5 seconds of interval.
5. Check if the back leak volume meets the specification.
Specified value
Below 20 cm
Note
If the measured value is out of specified value, replace

the injector.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-192
4-4. Dynamic Test for Injector Back leak Volume

1. Start the engine and warm up until the coolant temperature reaches to 60C.
2. Remove the injector return hose and seal the openings with screw type caps (included in tool kit).
3. Install the hoses from back leak test containers to return

nipples of injector.
4. Start the engine and let it run for 30 seconds at idle
speed.
5. Launon injector leak detection cycles with SCAN-100.
6. Check if the back leak volume meets the specification.

Specified value
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Below 38 ml
DIAGNOSIS
DI ENG SM - 2004.9
DI10-193
4-5 High Pressure Pump Test

1. Prepare the special tools for high pressure pump test
and thoroughly clean the system.
2. Remove the high pressure fuel supply pipe and install

the closed rail delivered with tool kit.
Specified value
40 Nm
* The figure is to show the test method. However, the

actual test operation should be done while the high
pressure pump is installed in vehicle.
3. Install the opposite end of the closed rail into the fuel rail
for test.
Specified value
40 Nm
4. Remove the high pressure fuel return hose and install

the transparent tube between the high pressure pump
and the return port of fuel rail for test.
DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-194
5. Connect the digital tester connector into the sensor
connector of fuel rail for test.
6. Disconnect the IMV connector and the fuel rail pressure
sensor connector.
7. Check if the measured value on the digital tester meets
the specified value.
Specified value
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Over 1,050 bar
DIAGNOSIS
DI ENG SM - 2004.9
DI10-195
PRESSURE LEAKAGE TEST WITH SCAN-100

1. When performing the static test for injector back leak Volume, the fuel pressure leakage test with SCAN-100
should be done simultaneously. And, the fuel pressure leakage test with SCAN-100 can be done separately.
2. Test Conditions:
No defective or faulty sensors and components in fuel system: checked by Scan-i
Coolant temperature: over 60C
3. The diagnosis procedures with SCAN-100 are as below:
1) Install the SCAN-100 to the diagnostic connector. Select
DIAGNOSTICS and press ENTER in MAIN MENU
screen. Select STAVIC and press ENTER in VEHICLE
SELECTION screen.
2) Select ECU and press ENTER in CONTROL UNIT

SELECTION screen.
3) Select LEAK DETECTION and press ENTER in

DIAGNOSIS
DI ENG SM - 2004.9
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DI10-196
4) If there are not any troubled conditions in TEST
CONDITION screen, press ENTER.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
DIAGNOSIS
DI ENG SM - 2004.9
2A
ELECTRIC SYSTEM LAYOUT

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

Tuner
Navigation unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
AM/FM radio amplifier
TV antenna
amplifier
Steering wheel angular

sensor
Rain sensing unit and ECM
Sun roof unit and motor
Interior temperature and

humidity sensor
Auto light sensor
Engine ECU
TCU and TCCU
TCU
ELECTRICAL SYSTEM
STAVIC - 2004.09
TCCU
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT

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

(Integrated type) Air conditioner
Receiver drier
AQS sensor
Ambient temperature sensor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
Brake pressure sensor
Fuse and relay box in engine

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

equipped vehicle)
beside battery positive
(+) terminal
Sub condenser
ELECTRICAL SYSTEM
STAVIC - 2004.09
Theft deterrent horn (under the

washer fluid reservoir)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
3. SWITCHES IN PASSENGER COMPARTMENT

Audio remote control switch on the steering wheel
Power button
Mode button
SEEK button Up
SEEK button Down
Mute button
Volume button Up
Volume button Down
4WD switch and rear washer/

wiper switch
Outside rearview mirror

adjusting and folding
switch
Window switches
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
Room lamp and sun roof switch

(multi meter integrated type)
Driver seat warmer

switch
Front defogger switch
Front fog lamp
Sun roof switch

Room lamp switch
(coupled operation
with door)
Hazard switch
Multi meter
Front room lamp switch
Outside rearview mirror and

rear glass heated switch
ESPOFF
Passenger seat
warmer switch
Multifunction switch and

steering wheel angular sensor
Passengers window
switch
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2A
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED VEHICLE)

Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switches
Front speaker (RH)

Sub woofer (amplifier
integrated type)
Front tweeter
speaker (RH)
GPS antenna
Center speaker
(RH)
AV head unit
Center
DVD changer s p e a k e r
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
Amplifier integrated sub woofer
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
DVD changer
Rear tweeter speaker (RH)
TV antenna amplifier (RH)
Rear speaker (RH)

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

Rear tweeter speaker (LH)
Tuner
DSP integrated
amplifier
Navigation unit
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
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10
2A
ELECTRIC COMPONENTS AND LAYOUT

1. WIRING HARNESS ARRANGEMENT
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ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
11
2. COMPONENTS LOCATOR
ELECTRICAL SYSTEM
STAVIC - 2004.09
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12
2A
FUSES AND RELAYS

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

Connector arrangement
Back of the fuse and relay box (after removal)
Fuses and relays
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ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
13
Arrangement of Fuses and Relays
Descriptions of Fuses and Relays

Fuse NO.
Capacity
Usage
Fuse NO.
Capacity
Usage
Generator (FFH, PTC)
Ef9
20A
AV System
60A
ABS, ABS/ESP
Ef10
30A
Glass HTD
SB3
30A
IGN KEY 2, Start RLY
Ef11
15A
SB4
30A
Condenser Fan (High)
Ef12
15A
Seat Warmer
SB5
30A
Condenser Fan (Low),

Ef13
20A
Sun Roof
Ef14
20A
4WD (TOD)
SB1
120A/140A
SB2
Condenser Fan
SB6
50A
ENG MAIN RLY
SB7
30A
Fuse Box BATT-2
SB8
30A
Blower (FRT)
SB9
30A
PWR Window (FRT)
Ef15
20A
Driver PWR Seat
SB10
30A
PWR Window (RR)
Ef16
10A
Tail Lamp (LH)
SB11
30A
Fuse Box BATT-1
Ef17
10A
Tail Lamp (RH)
Ef1
10A
A/C Compressor, A/C RLY
Ef18
7.5A
Illumination
Ef2
15A
Fog Lamp (FRT)
Ef19
15A
ENG ECU
Ef3
15A
DRL
Ef20
15A
Fuel Pump (GSL)
Ef4
10A
Horn
Ef21
15A
Head Lamp (High)
Ef5
15A
ENG SNR 1
Ef22
15A
RR Blower
Ef6
20A
FFH, Window Shield Glass
Ef23
20A
PWR Outlet (RR)
Ef7
30A
ABS, ABS/ESP
Ef24
20A
AV Head Unit, Tuner Unit
Ef8
15A
Head Lamp (Low)
Ef25
15A
Buzzer
Ef26
15A
Out Side Mirror
ELECTRICAL SYSTEM
STAVIC - 2004.09
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2A
2. INTERIOR FUSE AND ICM BOX

Interior Fuse Box
The interior fuse box is located in the lower area of driver side instrument panel.
To check the fuses, open the driver side door and remove the fuse box cover.
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ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
15
ICM(Integrated Control Module) Box

The ICM box is installed along with RK STICS on the bracket behind the Instrument panel undercover.
It contains an integrated module with around 14 relays according to the vehicle model. Relays in the module are installed
on the integrated circuit with a safety circuit. This system operates with small current (by using transistor) and minimizes the sparks that occur during operations (connection/disconnection) of relays; therefore its durability and wear
resistance has been greatly increased compared to the conventional relays.
Relays in the ICM box cannot be replaced respectively; so when the internal components (including relay) are defective,
ICM box should be replaced as an assembly.
RK STICS
ICM box
ELECTRICAL SYSTEM
STAVIC - 2004.09
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EFFECTIVE DATE
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2A
Printed Circuit Board Arrangement of ICM Box

The figure shows the internal arrangement of ICM box when the cover is removed and then disassembled.
The relays cannot be disassembled and replaced respectively; so the ICM box should be replaced as an
assembly when any internal components are defective.
Front view
Relay 15
(rear fog lamp)
Relay 3
(seat warmer, LH)
Relay 1 (spare 2)
Relay 4
(seat warmer, RH)
Relay 2
(O 2 sensor: gasoline)
Relay 9
(horn relay)
Relay 5
(wiper INT-LOW)
Relay 6
(wiper HIGH)
Relay 8
(door lock relay)
Relay 14
(flasher unit)
Relay 7
(power socket)
Relay 10
(front cigarette lighter
and power socket)
Relay 13
(theft deterrent relay)
Relay 11
(door unlock)
Relay 12
(drivers door unlock)
Buzzer 1
(Back sonar)
Chime bell circuit
Buzzer 2
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STAVIC - 2004.09
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17
Rear view
Relay 3
(spare 2)
Relay 1
Relay 4
Relay 2
Relay 9
Relay 5
Relay 8
Relay 15
Relay 6
Relay 7
Relay 12
Relay 13
Relay 11
Buzzer 2
ELECTRICAL SYSTEM
STAVIC - 2004.09
Relay 10
Relay 14
Buzzer 1
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2A
ICM Connector Arrangement (Based on Wiring Connectors)

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

! " #
! " # $

! "
' ! ! ! !! !"
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&
'
% & '
# $ % &
!# !$ !% !& !' "
ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
19
ICM Box Power Supply Circuit

The figure shows ICM box power supply circuit. For details, refer to the appropriate wiring diagrams.
1) Door lock relay / Cigarette lighter relay / Power outlet relay
This circuit is supplied the power through the relevant fuse and STICS. The supplied power magnetize the switch to
supply the power to the appropriate system.
To inspect this circuit, turn the switch on and check if the voltage from ICM box is within specified range. After then,
check the output through the ICM box.
Checking the condition of the relevant component in the system should be done before doing this inspection.
ELECTRICAL SYSTEM
STAVIC - 2004.09
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2A
2) Wiper HI and LO relay / Horn relay
The rain sensing system in this vehicle has a different control logic compared to conventional rain sensing system. In the
conventional rain sensing system, the rain sensor unit controls the wipers directly. However, in this vehicle, the rain
sensor communicates the data with STICS, and the STICS controls the wiper motor.
Signals from STICS to rain sensor unit contain the information that there is no rain under the current mode based on
following conditions;
- Washer switch is operating,
- Operating under MIST mode, or
- The multifunction wiper switch is in AUTO mode.
For more details, refer to the Rain Sensing Wiper section in this manual.
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ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
21
3) Flasher unit relay / Burglar relay / Chime bell
The relay and unit that controls the hazard warning flasher and turn
signal lamp is also installed in the ICM box as illustrated. Also, the
theft deterrent relay that operates the hazard warning flasher and the
theft deterrent horn is installed.
This vehicle has two separate horns in the engine compartment; a
horn (see figure) located in front of the battery is used for theft deterrent warning and beep sound during the operation of doors by remote
control key.
ELECTRICAL SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
2A
4) Seat warmer relay (front seats) / Back sonar

Each seat warmer installed in the front seats has its own relay in ICM box.
When pressing the seat warmer switch prepared for each front seat, the seat cushion and seatback get warm. The
thermistor in the seat maintains the warming temperature at around 45C by cutting off or connecting the power to the
heated wire.
The heated glass (defogger) system contains the windshield heated glass, outside rearview mirror heated glass, and
tailgate heated glass.
When the seat warmer switch is operated, the seat warmer relay in engine compartment fuse box supplies the power to
tailgate glass and outside rearview mirrors. This is controlled by STICS. However, the windshield heated glass (deicer)
is controlled by the separate control unit installed behind the driver side instrument panel undercover.
The fuse (30A) for tailgate heated glass and outside rearview mirror heated glass and the fuse (15A) for windshield
heated glass are in the engine compartment fuse box.
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ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
23
Tailgate Heated Glass, Outside Rearview Mirror Heated Glass (controlled by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
2. If the defogger switch is pressed again during the operation, the operation stops.
3. If the defogger switch is pressed again within 10 minutes after completion of the first operation, the defogger
system operates for 6 minutes just for once.
4. The defogger is not available when the ignition switch is in OFF position or the alternator is not running.
Windshield Heated Glass (controlled by separate unit)

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

In the parking aid system equipped vehicle, its control unit is installed inside of the rear quarter trim behind the drivers
seat. The buzzer for the back sonar is installed in ICM box. For more details, refer to Parking Aid System section in
this manual.
Back sonar
buzzer
ELECTRICAL SYSTEM
STAVIC - 2004.09
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2A
Removal and Installation of ICM Box

2. Unscrew the screws from driver side instrument panel
undercover and remove the undercover.
3. Unscrew the nuts and remove the ICM box.
4. Unscrew the connector mounting nuts from the back of the ICM box and disconnect the connector A and B.
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STAVIC - 2004.09
2A
25
Wiring Harness, Connector & Ground Location

1) W/H Engine room
ELECTRICAL SYSTEM
STAVIC - 2004.09
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2A
2) W/H Main
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STAVIC - 2004.09
2A
27
3) W/H Floor (LH)
ELECTRICAL SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
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2A
4) W/H Floor (RH)
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STAVIC - 2004.09
2A
29
5) W/H Air-con
Front air-con
ELECTRICAL SYSTEM
STAVIC - 2004.09
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AFFECTED VIN
30
2A
Rear air-con
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ELECTRICAL SYSTEM
STAVIC - 2004.09
2A
31
6) W/H Door
Front door
Rear door
ELECTRICAL SYSTEM
STAVIC - 2004.09
Tailgate door
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2A
7) W/H Roof
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STAVIC - 2004.09
2A
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8) W/H Seat
Drivers
Passengers
ELECTRICAL SYSTEM
STAVIC - 2004.09
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MEMO
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2A
2A - Electrical System (2005 ~)

Table of Contents
ELECTRIC SYSTEM LAYOUT .......................... 2A-2
1. Locations of units and sensors in passenger compartment
....................................................................................... 2A-2
2. Switches, units and sensors in engine compartment
(except engine related sensors and units) ................... 2A-4
3. Switches in passenger compartment ........................... 2A-6
4. System layout (based on DVD system equipped vehicle)
....................................................................................... 2A-8
ELECTRIC COMPONENTS AND LAYOUT .... 2A-10

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

1. Engine cmpartment fuse and relay box ..................... 2A-12
2. Interior fuse and ICM box .......................................... 2A-14
ELECTRICAL SYSTEM
RODIUS /STAVIC - 2005.07
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2A
ELECTRIC SYSTEM LAYOUT

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

Tuner
Navigation unit
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ELECTRICAL SYSTEM
RODIUS /STAVIC- 2005.07
2A
AM/FM radio amplifier
TV antenna
amplifier
Steering wheel angular

sensor
Rain sensing unit and ECM
Sun roof unit and motor
Interior temperature and

humidity sensor
Auto light sensor
Engine ECU
TCU and TCCU
TCU
ELECTRICAL SYSTEM
TCCU
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2A
2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT

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

(Integrated type) Air conditioner
Receiver drier
AQS sensor
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ELECTRICAL SYSTEM
2A
Brake pressure sensor
Fuse and relay box in engine

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

equipped vehicle)
beside battery positive
(+) terminal
Sub condenser
ELECTRICAL SYSTEM
Theft deterrent horn (under the

washer fluid reservoir)
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2A
3. SWITCHES IN PASSENGER COMPARTMENT

Audio remote control switch on the steering wheel
Power button
Mode button
SEEK button Up
SEEK button Down
Mute button
Volume button Up
Volume button Down
4WD switch and rear washer/

wiper switch
Outside rearview mirror

adjusting and folding
switch
Window switches
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ELECTRICAL SYSTEM
2A

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

Room lamp switch
(coupled operation
with door)
Hazard switch
Multi meter
Refogger switch
ESPOFF
Passenger seat
warmer switch
Multifunction switch and

steering wheel angular sensor
Passengers window
switch
ELECTRICAL SYSTEM
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2A
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED VEHICLE)

Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switches
Front speaker (RH)

Sub woofer (amplifier
integrated type)
Front tweeter
speaker (RH)
GPS antenna
Center speaker
(RH)
AV head unit
Center
DVD changer s p e a k e r
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
Amplifier integrated sub woofer
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ELECTRICAL SYSTEM
2A
DVD changer
Rear speaker (RH)

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

Tuner
DSP integrated
amplifier
Navigation unit
ELECTRICAL SYSTEM
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10
2A
ELECTRIC COMPONENTS AND LAYOUT

1. WIRING HARNESS ARRANGEMENT
CHANGED BY
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AFFECTED VIN
ELECTRICAL SYSTEM
2A
11
ELECTRICAL SYSTEM
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12
2A
FUSES AND RELAYS

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

Connector arrangement
Back of the fuse and relay box (after removal)
Fuses and relays
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ELECTRICAL SYSTEM
2A
13
Arrangement of Fuses and Relays
Descriptions of Fuses and Relays

Fuse NO.
Capacity
Usage
Fuse NO.
Capacity
Usage
Generator (FFH, PTC)
Ef9
20A
AV System
60A
ABS, ABS/ESP
Ef10
30A
Glass HTD
SB3
30A
IGN KEY 2, Start RLY
Ef11
15A
SB4
30A
Condenser Fan (High)
Ef12
15A
Seat Warmer
SB5
30A
Condenser Fan (Low),

Ef13
20A
Sun Roof
Ef14
20A
4WD (TOD)
SB1
120A/140A
SB2
Condenser Fan
SB6
50A
ENG MAIN RLY
SB7
30A
Fuse Box BATT-2
SB8
30A
Blower (FRT)
SB9
30A
PWR Window (FRT)
Ef15
20A
Driver PWR Seat
SB10
30A
PWR Window (RR)
Ef16
10A
Tail Lamp (LH)
SB11
30A
Fuse Box BATT-1
Ef17
10A
Tail Lamp (RH)
Ef1
10A
A/C Compressor, A/C RLY
Ef18
7.5A
Illumination
Ef2
15A
Fog Lamp (FRT)
Ef19
15A
ENG ECU
Ef3
15A
DRL
Ef20
15A
Fuel Pump (GSL)
Ef4
10A
Horn
Ef21
15A
Head Lamp (High)
Ef5
15A
ENG SNR 1
Ef22
15A
RR Blower
Ef6
20A
FFH, Window Shield Glass
Ef23
20A
PWR Outlet (RR)
Ef7
30A
ABS, ABS/ESP
Ef24
20A
AV Head Unit, Tuner Unit
Ef8
15A
Head Lamp (Low)
Ef25
15A
Buzzer
Ef26
15A
Out Side Mirror
ELECTRICAL SYSTEM
CHANGED BY
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AFFECTED VIN
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2A
2. INTERIOR FUSE AND ICM BOX

Interior Fuse Box
The interior fuse box is located in the lower area of driver side instrument panel.
To check the fuses, open the driver side door and remove the fuse box cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2A
15
ICM (Integrated Control Module) Box

The ICM box is installed along with RK STICS on the bracket behind the Instrument panel undercover.
It contains an integrated module with around 14 relays according to the vehicle model. Relays in the module are installed
on the integrated circuit with a safety circuit. This system operates with small current (by using transistor) and minimizes the sparks that occur during operations (connection/disconnection) of relays; therefore its durability and wear
resistance has been greatly increased compared to the conventional relays.
Relays in the ICM box cannot be replaced respectively; so when the internal components (including relay) are defective,
ICM box should be replaced as an assembly.
RK STICS
ICM box
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2A
Printed Circuit Board Arrangement of ICM Box

The figure shows the internal arrangement of ICM box when the cover is removed and then disassembled.
The relays cannot be disassembled and replaced respectively; so the ICM box should be replaced as an
assembly when any internal components are defective.
Front view
Relay 15
(rear fog lamp)
Relay 3
(seat warmer, LH)
Relay 1 (spare 2)
Relay 4
(seat warmer, RH)
Relay 2
(O 2 sensor: gasoline)
Relay 9
(horn relay)
Relay 5
(wiper INT-LOW)
Relay 6
(wiper HIGH)
Relay 8
(door lock relay)
Relay 14
(flasher unit)
Relay 7
(power socket)
Relay 10
(front cigarette lighter
and power socket)
Relay 13
(theft deterrent relay)
Relay 11
(door unlock)
Relay 12
(drivers door unlock)
Buzzer 1
(Back sonar)
Chime bell circuit
Buzzer 2
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2A
17
Rear view
Relay 3
(spare 2)
Relay 1
Relay 4
Relay 2
Relay 9
Relay 5
Relay 8
Relay 15
Relay 6
Relay 7
Relay 12
Relay 13
Relay 11
Buzzer 2
ELECTRICAL SYSTEM
Relay 10
Relay 14
Buzzer 1
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2A
ICM Connector Arrangement (Based on Wiring Connectors)

Never apply battery power from the rear of ICM printed circuit board directly to inspect internal circuit of the ICM box.
Otherwise, the precise internal circuits and safety circuit can be destroyed. When inspecting the power supply and
others, the connectors should be removed before starting the inspection.
The pin arrangements shown in the figure are also based on the connectors.
1 2 3 4
13 14 15 16
21 22 23 24
29 30 31 32 33 34
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9 10 11 12
17 18 19 20
25 26 27 28
35 36 37 38 39 40
ELECTRICAL SYSTEM
2A
19
ICM Box Power Supply Circuit

The figure shows ICM box power supply circuit. For details, refer to the appropriate wiring diagrams.
1) Door lock relay / Cigarette lighter relay / Power outlet relay
This circuit is supplied the power through the relevant fuse and STICS. The supplied power magnetize the switch to
supply the power to the appropriate system.
To inspect this circuit, turn the switch on and check if the voltage from ICM box is within specified range. After then,
check the output through the ICM box.
Checking the condition of the relevant component in the system should be done before doing this inspection.
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
2A
2) Wiper HI and LO relay / Horn relay
The rain sensing system in this vehicle has a different control logic compared to conventional rain sensing system. In the
conventional rain sensing system, the rain sensor unit controls the wipers directly. However, in this vehicle, the rain
sensor communicates the data with STICS, and the STICS controls the wiper motor.
Signals from STICS to rain sensor unit contain the information that there is no rain under the current mode based on
following conditions;
- Washer switch is operating,
- Operating under MIST mode, or
- The multifunction wiper switch is in AUTO mode.
For more details, refer to the Rain Sensing Wiper section in this manual.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2A
21
3) Flasher unit relay / Burglar relay / Chime bell
The relay and unit that controls the hazard warning flasher and turn
signal lamp is also installed in the ICM box as illustrated. Also, the
theft deterrent relay that operates the hazard warning flasher and the
theft deterrent horn is installed.
This vehicle has two separate horns in the engine compartment; a
horn (see figure) located in front of the battery is used for theft deterrent warning and beep sound during the operation of doors by remote
control key.
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
2A
4) Seat warmer relay (front seats) / Back sonar

Each seat warmer installed in the front seats has its own relay in ICM box.
When pressing the seat warmer switch prepared for each front seat, the seat cushion and seatback get warm. The
thermistor in the seat maintains the warming temperature at around 45C by cutting off or connecting the power to
the heated wire.
Parking Aid Sensors on Rear Bumper

In the parking aid system equipped vehicle, its control unit is installed inside of the rear quarter trim behind the drivers
seat. The buzzer for the back sonar is installed in ICM box. For more details, refer to Parking Aid System section in
this manual.
Back sonar
buzzer
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2A
23
Removal and Installation of ICM Box

2. Unscrew the screws from driver side instrument panel
undercover and remove the undercover.
3. Unscrew the nuts and remove the ICM box.
4. Unscrew the connector mounting nuts from the back of the ICM box and disconnect the connector A and B.
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
2A
Wiring Harness, Connector & Ground Location

1) W/H Engine room
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2A
25
2) W/H Main
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2A
3) W/H Floor (LH)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2A
27
4) W/H Floor (RH)
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
2A
5) W/H Air-con
Front air-con
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2A
29
Rear air-con
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
2A
6) W/H Door
Front door
Rear door
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Tailgate door
ELECTRICAL SYSTEM
2A
31
7) W/H Roof
ELECTRICAL SYSTEM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
2A
8) W/H Seat
Drivers
Passengers
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ELECTRICAL SYSTEM
2B
METER CLUSTER / INDICATOR DISPLAY

1. APPEARANCE
The instrument panel in this vehicle is different from conventional type of instrument panel. The meter cluster and
indicator display are separated. The meter cluster is located at the center of the dash panel, and the indicator display is
located in front of drivers seat.
Meter cluster
Coolant
temperature
gauge
RPM gage
Speedometer
Fuel level
gauge
Warning lamps and indicators
CLUSTER / WARNING & INDICATOR PANEL

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
2. CONNECTORS AND CIRCUIT DIAGRAM

Gauge Panel
Indicator Display
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2B
Circuit Diagram of Indicator Display

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
3. DESCRIPTIONS OF INDICATOR DISPLAY
Illumination lamp (bulb)
Connector B
Connector A
1. Immobilizer indicator
12. Seat belt reminder
2. Glow indicator
13. Low fuel level warning light
3. Winter mode indicator
14. Defogger indicator
4. Left turn signal indicator and hazard flasher
15. Door open warning light
5. Auto shift indicator (for automatic transmission)
16. High beam indicator
6. Right turn signal indicator and hazard flasher
17. Engine oil pressure warning light
7. 4WD CHECK warning light
18. Air bag warning light
8. 4WD LOW indicator
19. Water separator warning light
9. Engine check warning light
20. ABS warning light
10. Brake warning light
21. EBD warning light
11. Battery charge warning light
22. ESP warning light
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2B
4. FUNCTION DESCRIPTION AND INSPECTION OF METER CLUSTER

Meter Cluster
Tachometer Engine RPM Display
Danger range (red zone)
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the
current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700~800 rpm. The red zone (danger rpm
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Specification (VIN=13 0.1V, Temperature: 25C)
Description
Engine speed (rpm)
700
1000
2000
3000
4000
5000
6000
Tolerance (rpm)
+50
+100
+125
+150
+150
-100
-100
-125
-150
-150
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner
and then compare the value on tachometer with the reading from scanner.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear right wheel speed sensor through
ABS or ESP unit.
If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire inflation
pressures or different tire specifications.
Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field due to
lack of measuring conditions such as test equipment and preciseness.
1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester.
2. Check if the speedometer pointer is shaking and the abnormal noise sounds.
3. Eliminate the hysteresis by tapping the speedometer.
[Notice]
The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
(VIN=13 0.1V, Temperature: 25C)

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

STAVIC - 2004.09
2B
Fuel Level Gauge
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note
that this vehicle doesnt have a service hole for checking the fuel sender connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply
and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace
the fuel sender.
Tolerance and resistance value by indicating angle
Scale
Indicating angle ()
Full
(3/4)
1/2
(1/4)
Full (LFW)
40
20
- 20
- 40
Tolerance ()
+4~0
2.5
2.5
+ 1.5
Resistance()
38 1
67 1
99.5 1
247 1
260 1
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2B
Coolant Temperature Gauge
40o
0o
-40o
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by
coolant temperature is as shown below.
Indicating angle
Tolerance
Coolant temperature
- 40 (H)
0C (1/2)
+40(C)
2.5
+0C
+5C
- 5C
+1C
70C ~ 110C
Over 125C
40C
Measurement of coolant temperature sensor resistance

Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out
of specified range.
Resistance value by coolant temperature:
20C :
2449
5 %
50C :
826
5 %
80C :
321
5 %
100C :
112
5 %
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator
related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2B
11
TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter
Reset button
* Press and hold (over 1 sec.)
Trip odometer TRIP A and TRIP B will be reset to 0. (However, only the corresponding driving
range will be set to 0.)
* Press shortly (between 0.1 ~ 1 sec.)
The mode changes in order as shown in the figure.
ODO
TRIP A
TRIP B
Displaying range: 0 ~ 999999 km
Displaying range: 0.0 ~ 999.9 km
(The odometer stops at 999999 km.)
Increment: 0.1 km
Increment: 0.1 km
Increment: 1 km

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2B
5. WARNING & INDICATOR PANEL

This indicator comes on when the ignition
switch is turned on and stays on for a short
time or may go off right away. When the glow
plugs are sufficiently heated for cold starting,
the light will go out. Then, start the engine.
In the vehicle equipped with direct injection
type engine, this indicator may come on very
shortly or may not come on.
Glow Indicator (For Diesel Engine)
This indicator indicates the operating conditions of immobilizer system. This indicator
comes on when the ignition key is communicating with the engine control unit (during
engine starting) and goes out after starting
the engine. If this indicator blinks, it may indicate that there is something wrong in the immobilizer system.
Parking Reverse Neutral Driving
The indicator comes on when the Winter mode (W) switch near the gear selector lever is pressed. Use this mode
to drive off smoothly under icy and slippery road. In this mode, the vehicle
drives off with second gear in forward
and reverse driving.
Driving gears
This indicator shows the automatic

transmission selector lever position.
When the selector lever is at "D" position while driving, "D" indicator and currently selected gear indicator are coming on. If you move the selector lever to
left or right direction, only the selected
gear indicator comes on.
Winter Mode Indicator

(For Automatic Transmission)
Auto Shift Indicator

(for automatic transmission)
Engine Check Warning Light
Battery Charge Warning Light
Immobilizer Indicator
4WD CHECK Warning Light /

4WD LOW indicator
4WD CHECK Warning Light
This warning light comes on when the ignition switch is turned to ON and should go
out if the system is normal. If 4WD CHECK
warning light stays on or 4WD LOW indicator blinks continuously, it may indicate that
there is something wrong in the immobilizer
system.
4WD LOW indicator*
When shifting the driving mode between 4WD
LOW and 4WD HIGH, this indicator blinks
until the shifting operation is completed. After
completion of mode change, the indicator goes
out.
Brake Warning Light

When the ignition is switched on, this warning light comes on and should go out. This
warning light comes on when the parking
brake is applied and/or the brake fluid level is
lower than specified level. If the vehicle is
driven for over 2 seconds (over 10 km/h) while
the parking brake is applied, the parking brake
warning light comes on and warning buzzer
sounds.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
This warning light comes on when the

ignition switch is turned to ON and goes
out if the engine is in normal condition. If
the light stays on or comes on while
driving, some of engine control components including sensors and devices are
defective. When this warning light comes
on, the vehicle operates in safety mode
to maintain minimum driving conditions
and to prevent the system from being
damaged. In this mode, the engine driving force may be decreased or the engine may stall. For more details, refer to
Engine section in this manual.

ignition switch is turned on and go off
when the engine is started. If this light
doesnt go off after engine starting or
comes on while driving, it means there
is a malfunction in the system. The battery voltage is also displayed on the multi
meter.
Seat Belt Reminder

The seat belt warning light comes on
and the seat belt warning chime sound
for 6 seconds when the ignition switch
is turned to ON position unless the
drivers seat belt is securely fastened.
This reminding operation stops when
the driver fastens the seat belt even
during its operation period.
STAVIC - 2004.09
2B
13
Windshield Heated Glass (controlled by separate unit)

The windshield heated glass control unit is installed on the
bottom of driver side Instrument panel. Whenever pressing the
switch, the windshield heated glass operates for 12 minutes
and turns off if pressed again during its operation. If the switch
is pressed again, it operates another 12-minute operation.
Tailgate Heated Glass, Outside Rearview Mirror
Heated Glass (controlled by STICS)
The outside rearview mirror heated glass operates for 12 minutes when turning on the seat warmer switch while the engine
is running. If the seat warmer switch is pressed again within
10 minutes after completion of the first operation, the seat
warmer operates for 6 minutes just for once.
When the water level inside water separator

in fuel filter exceeds a certain level, this warning light comes on and buzzer sounds. Also,
the driving force of the vehicle decreases. If
these conditions occur, immediately drain the
water from fuel filter and water separator.
For the draining procedures, refer to Engine
section in this manual.
Defogger Indicator
Water separator warning light
ABS / EBD ESP Warning Light

ESP Warning Light
Engine Oil Pressure Warning

Light
Door Open Warning Light

This light comes on when a door or tailgate is either opened or not closed
completely. If you drive over 10 km/h of
vehicle speed without closing the door,
the warning light blinks.

ignition is switched on and should go
out when the engine is started. If the
light comes on while driving, it indicates
that the oil pressure is dangerously low.
Check the oil lines and lubricating system for leak.
This warning light indicates that the fuel

will soon be exhausted. The time it takes
to turn on, however, varies according to
the vehicle operating conditions or gradient of the road.
When the ignition is switched on, this

warning light illuminates and then
should go out, to confirm that the air
bag is operational. If it does not come
on, or if it does not go out, or if it flashes
or illuminates continuously while
driving, it means that there is malfunction in the system.

STAVIC - 2004.09
EBD Warning Light

This warning light comes on when the ignition switch is turned to ON and should go out
if the system is normal. If the EBD system is
abnormal, both EBD warning light and ABS
warning light come on simultaneously.
ABS Warning Light
if the system is normal.
Air Bag Warning Light

Low Fuel Level Warning Light
This warning light comes on when pressing

the ESP OFF switch or the ESP system is
defective. If the ESP function operates while
driving, this warning light flickers and the
alarm sounds.
[NOTE]
The vehicle equipped with ABS
performs self-diagnosis on the system
when the engine is started and drives
off. During the diagnosis, brake pedal
vibration and noise may be apparent
when the driving motors discharges
the hydraulic pressure from the
internal hydraulic device. This means
the ABS is properly functioning.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2B
6.REMOVAL AND INSTALLATION OF METER CLUSTER AND INDICATOR

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

STAVIC - 2004.09
2B
15
4. Carefully pull out the center speakers and disconnect the connectors.
5. Remove the screws and take out the front cover from the instrument panel.
6. Disconnect all switch connectors including TRIP switch connector (2) during removal of the front cover.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2B
7. Unscrew four screws and pull out the meter cluster housing.
8. Disconnect the connector and remove the meter cluster housing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2B
17
Indicator Display
1. Remove the indicator display cover.
2. Unscrew the screws and pull out the indicator display

housing.
3. Disconnect the connector and remove the indicator

display housing.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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2B
2B - Cluster / Warning
& Indicator Panel (2005 ~)
Table of Contents
METER CLUSTER / INDICATOR DISPLAY ...... 2B-3
1. Appearance ................................................................. 2B-3
2. Connectors and circuit diagram ................................... 2B-4
3. Descriptions of indicator display .................................. 2B-6
4. Function description and inspection of meter cluster ... 2B-7
5. Warning & indicator panel ......................................... 2B-12
6. Removal and installation of meter cluster and indicator
display ...................................................................... 2B-14

RODIUS/STAVIC - 2005.07
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
METER CLUSTER / INDICATOR DISPLAY

1. APPEARANCE
The instrument panel in this vehicle is different from conventional type of instrument panel. The meter cluster and
indicator display are separated. The meter cluster is located at the center of the dash panel, and the indicator display is
located in front of drivers seat.
Meter cluster
Coolant
temperature
gauge
RPM gage
Speedometer
Fuel level
gauge
Warning lamps and indicators

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
2. CONNECTORS AND CIRCUIT DIAGRAM

Meter Cluster
Warning Lamps and Indicators
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

2B
Circuit Diagram of Indicator Display

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2B
4. FUNCTION DESCRIPTION AND INSPECTION OF METER CLUSTER

Meter Cluster
Tachometer Engine RPM Display
Danger range (red zone)
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the
current number of engine revolutions.
Under the normal engine operating temperature, the proper idling speed is 700~800 rpm. The red zone (danger rpm
range) starts from 4,500 rpm.
1. Connect the tachometer for tune-up test and start the engine.
2. Eliminate the hysteresis by tapping the tachometer.
3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Specification (VIN=13 0.1V, Temperature: 25C)
Description
Engine speed (rpm)
700
1000
2000
3000
4000
5000
6000
Tolerance (rpm)
+50
+100
+125
+150
+150
-100
-100
-125
-150
-150
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in
tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner
and then compare the value on tachometer with the reading from scanner.

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

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

2B
Fuel Level Gauge
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note
that this vehicle doesnt have a service hole for checking the fuel sender connector in the fuel tank.
The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply
and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram).
When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace
the fuel sender.
Scale
Indicating angle ()
Full
(3/4)
1/2
(1/4)
Full (LFW)
40
20
- 20
- 40
Tolerance ()
+4~0
2.5
2.5
+ 1.5
Resistance()
38 1
67 1
99.5 1
247 1
260 1
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored.

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2B
Coolant Temperature Gauge
40o
0o
-40o
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by
coolant temperature is as shown below.
Indicating angle
Tolerance
Coolant temperature
- 40 (H)
0C (1/2)
+40(C)
2.5
+0C
+5C
- 5C
+1C
70C ~ 110C
Over 125C
40C
Measurement of coolant temperature sensor resistance

Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out
of specified range.
Resistance value by coolant temperature:
20C :
2449 5 %
50C :
826
5 %
80C :
321
5 %
100C :
112
5 %
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator
related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

2B
11
TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter
Reset button
* Press and hold (over 1 sec.)
Trip odometer TRIP A and TRIP B will be reset to 0. (However, only the corresponding driving
range will be set to 0.)
* Press shortly (between 0.1 ~ 1 sec.)
The mode changes in order as shown in the figure.
ODO
TRIP A
TRIP B
Displaying range: 0 ~ 999999 km
(The odometer stops at 999999 km.)
Increment: 0.1 km
Increment: 0.1 km
Increment: 1 km

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2B
5. WARNING & INDICATOR PANEL

This indicator comes on when the ignition
switch is turned on and stays on for a short
time or may go off right away. When the glow
plugs are sufficiently heated for cold starting,
the light will go out. Then, start the engine.
In the vehicle equipped with direct injection
type engine, this indicator may come on very
shortly or may not come on.
Glow Indicator (For Diesel Engine)
This indicator indicates the operating conditions of immobilizer system. This indicator
comes on when the ignition key is communicating with the engine control unit (during
engine starting) and goes out after starting
the engine. If this indicator blinks, it may indicate that there is something wrong in the immobilizer system.
Parking Reverse Neutral Driving
The indicator comes on when the Winter mode (W) switch near the gear selector lever is pressed. Use this mode
to drive off smoothly under icy and slippery road. In this mode, the vehicle
drives off with second gear in forward
and reverse driving.
Winter Mode Indicator

(For Automatic Transmission)
2 3 4 5
Driving gears
This indicator shows the automatic

transmission selector lever position.
When the selector lever is at "D" position while driving, "D" indicator and currently selected gear indicator are coming on. If you move the selector lever to
left or right direction, only the selected
gear indicator comes on.
Auto Shift Indicator

(for automatic transmission)
Immobilizer Indicator
4WD CHECK Warning Light /

4WD LOW indicator
This warning light comes on when the ignition switch is turned to ON and should go
out if the system is normal. If 4WD CHECK
warning light stays on or 4WD LOW indicator blinks continuously, it may indicate that
there is something wrong in the immobilizer
system.
Seat Belt Reminder

The seat belt warning light comes on
and the seat belt warning chime sound
for 6 seconds when the ignition switch
is turned to ON position unless the
drivers seat belt is securely fastened.
This reminding operation stops when
the driver fastens the seat belt even
during its operation period.
4WD LOW indicator*

When shifting the driving mode between 4WD
LOW and 4WD HIGH, this indicator blinks
until the shifting operation is completed. After
completion of mode change, the indicator goes
out.
Brake Warning Light
Battery Charge Warning Light
When the ignition is switched on, this warning light comes on and should go out. This
warning light comes on when the parking
brake is applied and/or the brake fluid level is
lower than specified level. If the vehicle is
driven for over 2 seconds (over 10 km/h) while
the parking brake is applied, the parking brake
warning light comes on and warning buzzer
sounds.

ignition switch is turned on and go off
when the engine is started. If this light
doesnt go off after engine starting or
comes on while driving, it means there
is a malfunction in the system. The battery voltage is also displayed on the multi
meter.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Low Fuel Level Warning Light

This warning light indicates that the fuel
will soon be exhausted. The time it takes
to turn on, however, varies according to
the vehicle operating conditions or gradient of the road.

2B
Windshield Heated Glass Tailgate

Heated Glass, Outside Rearview Mirror Heated Glass (controlled by STICS)
The outside rearview mirror heated glass operates for 12 minutes when turning on the seat
warmer switch while the engine is running. If
the seat warmer switch is pressed again
within 10 minutes after completion of the first
operation, the seat warmer operates for 6 minutes just for once.
Defogger Indicator
13
When the water level inside water separator

in fuel filter exceeds a certain level, this warning light comes on and buzzer sounds. Also,
the driving force of the vehicle decreases. If
these conditions occur, immediately drain the
water from fuel filter and water separator.
For the draining procedures, refer to Engine
section in this manual.
Water separator warning light
This warning light comes on when the ignition switch is turned to ON and goes out
if the engine is in normal condition. If the
light stays on or comes on while driving,
some of engine control components including sensors and devices are defective.
When this warning light comes on, the
vehicle operates in safety mode to maintain minimum driving conditions and to prevent the system from being damaged. In
this mode, the engine driving force may
be decreased or the engine may stall. For
more details, refer to Engine section in
this manual.
Engine Check Warning Light
ABS / EBD ESP Warning Light

ESP Warning Light
Engine Oil Pressure Warning

Light
ignition is switched on and should go
out when the engine is started. If the
light comes on while driving, it indicates
that the oil pressure is dangerously low.
Check the oil lines and lubricating system for leak.
This warning light comes on when pressing

the ESP OFF switch or the ESP system is
defective. If the ESP function operates while
driving, this warning light flickers and the
alarm sounds.
EBD Warning Light
if the system is normal. If the EBD system is
abnormal, both EBD warning light and ABS
warning light come on simultaneously.
ABS Warning Light
if the system is normal.
Door Open Warning Light
Air Bag Warning Light
This light comes on when a door or tailgate is either opened or not closed
completely. If you drive over 10 km/h of
vehicle speed without closing the door,
the warning light blinks.
When the ignition is switched on, this

warning light illuminates and then
should go out, to confirm that the air
bag is operational. If it does not come
on, or if it does not go out, or if it flashes
or illuminates continuously while
driving, it means that there is malfunction in the system.

[NOTE]
The vehicle equipped with ABS
performs self-diagnosis on the system
when the engine is started and drives
off. During the diagnosis, brake pedal
vibration and noise may be apparent
when the driving motors discharges
the hydraulic pressure from the
internal hydraulic device. This means
the ABS is properly functioning.
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6.REMOVAL AND INSTALLATION OF METER CLUSTER AND INDICATOR

DISPLAY
Meter Cluster
front cup holder.
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15
6. Disconnect all switch connectors including TRIP switch connector (2) during removal of the front cover.

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7. Unscrew four screws and pull out the meter cluster housing.
8. Disconnect the connector and remove the meter cluster housing.
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Indicator Display
1. Remove the indicator display cover.
2. Unscrew the screws and pull out the indicator display

housing.
3. Disconnect the connector and remove the indicator

display housing.

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REKES + STICS (RK STICS)

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

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

various relays, chime and
buzzer controlled by STICS
RK STICS
STAVIC - 2004.09
This diagnosis connector is used for

Added the escort and
panic function
STICS key coding and trouble

diagnosis.
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2. TRANSMITTER CODING
Coding process:
1. Remove the ignition key from key hole.
2. Connect the No. 3 terminal (REKES coding) and No. 16 terminal (battery+) on the diagnosis connector with a
jumper cable.
3. Press any button on the remote control key shortly. (approx. 0.5 sec.)
4. When the coding is successful, turn signal lamps blink once and warning horn sounds once.
5. If the coding has failed, repeat 1 to 4 steps.
Connector pin descriptions

1
IG1
REKES (for coding)
Ground
Signal ground
CAN_High
ECU
ABS
Air bag
10
TGS
11
TCU
12
FFH (for diagnosis)
13
TCCU
14
CAN_Low
15
REKES (for diagnosis)
16
Battery+
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3. DESCRIPTIONS
Below table shows the major differences compared to the previous vehicle model before year 2004. For whole functions
and details, refer to corresponding section.
Item
RK STICS
Door lock
The door unlock output is sent to all doors once for 0.5 seconds when the LOCK
signal is inputted into unit within 0.5 seconds after closing the drivers or
passengers door. This is regardless of key in or key out. It is to prevent the
doors from locking due to impact when the door is closed.
Auto door unlock
Previously, G-sensor in STICS outputs auto door unlock signal if the vehicle
collides over 15 km/h of vehicle speed. However, the air bag system is installed
in this vehicle as a basic equipment. When a collision, the Auto Door Unlock
function is activated by using a collision signal from the air bag module.
Front room lamp
1. When receiving the unlock signal from remote control key with the door
closed, the front room lamp comes on for 30 seconds.
2. When receiving the unlock signal again during the time lagging operation,
another 30 seconds will be extended from unlock point.
Time lag power window control
The power window can be operated for 30 seconds after removing the ignition
key from key switch. This lagging operation stops when closing the door.
Parking brake warning
When the vehicle speed signal is inputted with the parking brake applied, the
warning light blinks and the chime buzzer in ICM box continuously sounds for 0.
6 seconds with 0.3 seconds of pausing time (when driving over 10 km/h of vehicle
speed for more than 2 seconds).
Tail lamp auto cut (battery saver)
1. Turns on or off the tail lamp relay according to the tail lamp switch
operations.
2. The tail lamp relay is turned off (auto-cut) when removing the ignition key
and opening and closing the door while the tail lamp switch is turned on.
Theft deterrent alarm
The hazard warning relay in ICM box outputs when the remote control key is
operated or the theft deterrent alarm is activated. At this time, separate warning
horn sounds.
Panic alarm operating only

(ON: IGN S/W in)
1. The theft deterrent horn sounds for 27 seconds when receiving the panic
signal from the remote control key.
2. The panic alarm is turned off when receiving any signal from the remote
control key during the panic alarm operation.
3. This function works under armed mode.
Headlamp control (escort)
1. The headlamp control supplies the power to headlamp relay for 20 seconds and
turns off when receiving the escort signal from the remote control key with the
ignition key off (if the escort signal is inputted again, it will be extended once for
20 seconds). However, the power supply and output is activated only when the
vehicle is in armed mode activated by remote control key.
2. The headlamp relay output is turned off immediately after receiving the
remote control lock signal during its operation (however, signals other than
lock signal from remote control key will be ignored).
3. The headlamp relay output is immediately turned off when the key is turned
to ON position during its operation (this function is also activated under
remote starting).
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4. CONNECTOR ARRANGEMENT (UNIT)
NO.
Description
Status
NO.
Description
Status
Wiper relay (HI)
Output
38
Hood switch
Input
Tailgate heated glass/outside rearview mirror relay
Output
39
Rear LH/RH door switch
Input
Drivers door unlock
Output
40
Seat belt warning light
Output
Coding
41
Wiper motor relay (parking)
Input
Door lock
Output
42
Input
ALT_D
Input
43
Tailgate switch
Input
Power window relay
Output
44
Tail lamp switch
Input
Ground
45
Passengers door lock switch
Input
Headlamp relay
Output
46
Passengers door unlock switch
Input
10
Door unlock
Output
47
Diagnosis (KWP 2000)
Input/Output
11
Passengers door lock switch
Input
48
Rear door lock switch
Input
12
Chime buzzer (in ICM box)
Output
49
Washer switch
Input
13
Front room lamp
Output
50
Intermittent auto switch
Input
14
Wiper relay (LO)
Output
51
Door opening indication
Output
15
Tail lamp relay
Output
52
Intermittent volume
Input
16
V+
53
Key hole illumination
Output
17
Engine start relay
54
Headlamp relay
Output
18
Ground
19
Theft deterrent horn
Output
56
20
Rear room lamp
Output
57
21
IGN 2
Input
58
22
IGN 1
Input
59
23
Parking brake warning light
Output
60
24
Tailgate glass and outside rearview mirror heated glass
Input
61
25
Seat belt switch
Input
62
26
Rain sensor input
Input
63
27
Key reminder switch
Input
64
28
Tailgate lock switch
Input
65
29
Drivers door lock switch
Input
66
Input/Output
67
Output
68
Input
69
30
31
Hazard flasher relay (in ICM box)
32
Output
55
33
Theft deterrent alarm selection switch
Input
70
34
Rain sensor output
Output
71
35
Parking brake switch
Input
72
36
Drivers door switch
Input
73
37
Passengers door switch
Input
74
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5. SPECIFICATIONS
1) Electrical Performance
Item
Requirement
Remark
Rated voltage
DC 12 V
Operating voltage
DC 9~16 V
-30C ~ +80C
Reserved temperature
-40C ~ +85C
Max. operating humidity
95%
Resistible voltage
24 V
Insulating resistance
No heat and fire due to the
Confined with PCB, waterproof and coating that requires
current leaks.
the insulation.
below 4.0 mA
IGN = OFF, Full output load = OFF, 90 seconds (after
(below 6.0 mA)
received the signals), No input changes for 2 seconds
below 1.2 V
Pin no. 8 and 2, 3, 5, 7, 10, 12, 13, 15, 19, 20, 23, 40, 47,
below 2.0 V
51, 53, 54
Parasitic current
Voltage drop
Should operate normally within this range.
Pin no. 8 and 9, 13, 15, 23, 40, 51, 53
2) Chattering of Input Signals

1. Vehicle speed input:
The vehicle speed calculating time is 1.0 seconds. The elapsed time of 1.5 seconds after IGN 1 switch :ON is not
included.
2. 20 ms target input:
Wiper motor A/S (parking) terminal
3. 100 ms target input switch
All switches except wiper motor A/S (parking) terminal
3) Time Tolerance
1. If not indicated, time tolerance will be 10%.
However, if less than 500 ms, time tolerance will be 50 ms.
2. The time indicated in each function does not include chattering processing time from switch input changing point.
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RK Stics
1
IGN 1
ON = BAT (IGN ON or START)
IGN 2
ON = BAT (IGN ON)
ALT_D
ON = BAT equivalent (engine running)
Key reminder (door ajar warning switch)
IGN = BAT (Key in)
Drivers door switch
OPEN = GND
Passengers door switch
OPEN = GND
Rear door switch
OPEN (one of rear seat) = GND
BAT = Battery
CLOSE (one of rear seat) = OPEN

8
Tailgate switch
OPEN = GND
Central door lock switch
ON = GND
10
Central door unlock switch
ON = GND
11
Drivers door lock/unlock switch
LOCK = OPEN, UNLOCK = GND
Passengers door lock/unlock switch
Rear door lock/unlock switch
UNLOCK (one of rear seat) = GND
12
LOCK (one of rear seat) = OPEN

Tailgate lock/unlock switch
16
Hood switch
OPEN = GND
17
Tailgate switch
ON = GND
18
Defogger switch
ON = GND
19
Seat belt switch
Fastened = OPEN, Unfastened = GND
20
ON = GND (applied)
21
Washer switch
ON = GND
22
Intermittent switch
ON = GND
23
Intermittent volume
0 ~ 50 k (for intermittent wiper)
24
Wiper motor (parking)
ON = GND
25
Rain sensor unit input
ON = GND (during sending from rain sensor)
26
Rain sensor unit output
ON = GND (during sending from RK STICS)
27
Hazard warning flasher selection switch
ON = GND
28
Collision sensor
ON = 200 ms output (LOW)
29
Speed sensor
Vehicle speed signal (OPEN COLLECTOR)
30
Coding
ON = BAT
31
Diagnosis (K-Line)
ON = BAT (during Installation or
13
communication)
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6. FUNCTIONS OF RK STICS
1) Wiper Control
Wiper MIST and Washer Coupled Wiper
1. The wiper relay is turned on 0.3 seconds (T1) after turning ON the washer switch for 0.2 ~ 0.59 seconds (T2) with
the ignition key ON, and it is turned off when the parking terminal is turned off.
2. The wiper relay is turned on 0.3 seconds (T1) after turning ON the washer switch over 0.6 seconds (T2) with the
ignition key ON, and it is turned on three times immediately after turning off the washer switch.
T1: within 0.5s
RK STICS
STAVIC - 2004.09
T2: over 0.6s
T3: one wipter cycle
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3. If the washer operating signal is inputted while the wipers are operating in intermittent or AUTO mode, the system
stores the previous intermittent interval and operates the washer coupled wiper. After then, the wiper operation
returns back to intermittent or AUTO mode with the stored operating interval.
T1: within 0.3s
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T2: 0.2 ~ 0.59s
T3: over 0.6s
T4: 3 cycles
T5: operationg interval
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Rain Sensor Coupled Wiper

If equipped with RE-STICS rain sensor, has following operation system.
1. System layout
This vehicle has a different wiper control logic compared to other models. As shown in the system diagram, the rain
sensor unit does not control wiper directly. The rain sensor unit sends infrared rays signal through LED and then
receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly.
For more details, refer to rain sensing wiper section in this manual.
Multi-function (wiper)
switch
Rain
sensor
RESTICS
Wiper LO
Wiper HI
Wiper motor
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2. Rain sensing operation point

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

The wiper relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (ex: from 0 to
1) (while the ignition key is in ON position, the wiper switch is in AUTO position, and the wiper motor is in Parked
position). However, the wiper motor can be operated only when the rain sensor detects the Rain Detected signal.
* If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle.
SENSITIVITY
RAIN SENSOR
Rain Detected
OFF
WIPER RELAY
LO
ON
OFF
T1: 1 cycle
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4. Wiper operation when the wiper parking terminal is grounded

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

1) The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from
3 during receiving the malfunction signal (1) from the rain sensor (while the ignition key is in ON position and the
wiper switch is in AUTO position).
SENSITIVITY
RAIN SENSOR
Malfunction signal (1): Yes
Malfunction signal (1): No
WIPER RELAY
ON
LO
OFF
T1: 1 cycle
wiper switch is in AUTO position).
SENSITIVITY
RAIN SENSOR
WIPER RELAY
ON
LO
OFF
T1: 1 cycle
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wiper switch is in AUTO position). Also, the wiper relay (LO) is turned on and the wiper motor runs one cycle when
the wiper sensitivity is changed to 2 from 1 during receiving the ground fixed or IGN fixed signal from the rain
sensor.
SENSITIVITY
RAIN SENSOR
WIPER RELAY
ON
LO
OFF
T1: 1 cycle
Speed Sensitive INT (Intermittent) Wiper

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

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

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

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

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

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

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

Front Room Lamp
1. The front room lamp comes on when opening the drivers door or passengers
door while the front room lamp switch is at door coupled position and the
key reminder switch is turned off.
2. The room lamp stays on for 2 seconds (T1) and then decays through 3
seconds (T2) when closing the drivers door or passengers door.
3. The room lamp output should stop immediately after turning on the ignition
key during decaying operation.
Door coupled front

room lamp switch
4. The front room lamp comes on for 30 seconds (T3) when receiving the
unlock signal from the remote control key while the door is closed.
5. The front room lamp output period is extended by 30 seconds (T3) when receiving the unlock signal from the remote
control key again during output.
6. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2.
7. The room lamp output stops immediately after receiving the lock signal from drivers door and passengers door
lock switch while the drivers door and passengers door are closed.
RECEIVE
NO SIGNAL
OUTPUT
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
2C
Rear Room Lamp

1. The rear room lamp comes on when opening the rear door while the door
coupled rear room lamp switch is pressed (except for luggage room lamp).
2. The rear room lamp extends its lighting period by 5 seconds when closing
the rear door.
3. The room lamp output stops immediately after turning the ignition key to
ON position during the extended period.
4. The room lamp output stops immediately after receiving the lock signal
from the rear door lock switch or the remote control key while the rear door
is closed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Door coupled rear

room lamp switch
RK STICS
STAVIC - 2004.09
2C
25
8) Ignition Key Hole Illumination (Except For Immobilizer)

1. The ignition key hole illumination comes on when opening the drivers door or passengers door while the ignition
key is removed.
2. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1.
3. The output stops when the ignition key is turned to ON position.
4. The output stops when receiving the lock signal from the remote control key (under armed mode).
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2C
9) Battery Saver (Tail Lamp Auto Cut)

1. The tail lamp is turn on or off according to the operations of the multifunction tail lamp switch.
2. The tail lamp relay is turned off (auto cut) when opening and closing the drivers door after removing the ignition key
without turning off the tail lamp.
3. Tail lamp relay is turned on when inserting the ignition key into ignition switch again after step 2 operation.
4. The tail lamp relay is turned off (auto cut) when opening and closing the drivers door while the ignition key is
removed and the tail lamp is turned on.
AUTO CUT
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
AUTO CUT
RK STICS
STAVIC - 2004.09
2C
27
10) Defogger Timer

1. The system outputs the tailgate, windshield and outside rearview mirror heated glass ON signal when turning on
the defogger switch (while the engine is running).
2. The output stops when turning on the defogger switch again during its operation.
3. The output is ON only for 6 minutes (T3) when turning ON the rear defogger switch within 10 minutes (T2) after
completion of output.
When turning on the defogger switch again within 10 minutes (T2) after completion of initial 12 minutes (T1) of
output, the output comes on for 6 minutes (T3) again once only.
4. The output stops when the IGN 2 switch is turned to OFF position or the ALT is OFF.
OVER 9V
BELOW 9V
REAR DEFOGGER
SWITCH
REAR DEFOGGER
RELAY
T1: 12 min.
T2: 10 min.
T3: 6 min.
This vehicle has the windshield heated glass and the tailgate and outside rearview mirror heated glass. The heater relay
in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse (15A) is located in the engine
compartment fuse box.
Defogger switch
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
2C
11) Door LOCK/UNLOCK Control

Door Lock/Unlock by Door Lock Switch
1. The door lock system outputs LOCK for 0.5 seconds (T1) when positioning the drivers or passengers door lock
switch to lock position (while the drivers and passengers door lock switch is in UNLOCK position).
2. The door lock system outputs UNLOCK for 0.5 seconds (T2) when positioning the drivers or passengers door
lock switch to unlock position.
3. LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK by other
functions.
4. The door lock/unlock system is not working regardless of the door lock switch positions when connecting the
battery.
5. All door lock signals are UNLOCK for 0.5 seconds (T4) just for once when receiving the LOCK signal within 0.5
seconds (T3) after closing the drivers or passengers door. However, this operation is regardless of the ignition key
positions.
[Notice]
This function prevents the door from locking by shock when slamming a door while the ignition key is inserted into the key
switch hole.
T3: within 0.5s
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
29
Door Lock/Unlock by Central Door Lock Switch

1. The door lock system outputs LOCK for 0.5 seconds (T1) when pressing LOCK button on the central door lock
switch.
2. The door lock system outputs UNLOCK for 0.5 seconds (T2) when pressing UNLOCK button on the central door
lock switch.
3. The LOCK or UNLOCK inputs from the central door lock switch in armed mode are ignored.
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
2C
Door LOCK/UNLOCK by Remote Control Key

1. The door lock system outputs LOCK for 0.5 seconds (T2) when receiving LOCK signal from the remote control
key.
2. The door lock system outputs UNLOCK signal for drivers door for 0.5 seconds (T3) when receiving UNLOCK
signal from the remote control key.
3. The door lock system outputs UNLOCK signal for all doors for 0.5 seconds (T3) when receiving UNLOCK signal
again within 30 seconds (T1) after receiving the first UNLOCK signal (second unlock step).
4. The second unlock step is canceled when receiving LOCK signal within 30 seconds (T1) after receiving the first
UNLOCK signal.
NO SIGNAL
T1: within 30s
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
31
Auto Door Lock

1. The door lock system outputs LOCK when the vehicle speed stays over 50 km/h. However, it doesnt output
LOCK when all doors are locked or failed.
2. If any of doors is unlocked after outputting LOCK in step 1, outputs LOCK up to 5 times (except step 1) with
interval of one second.
3. If any of doors is unlocked after 5 times of LOCK outputs, the door is regarded as FAIL.
4. If the door that was regarded as fail changes (UNLOCKLOCK) to unlock, only one LOCK output will be done.
5. If the door that was LOCK is changed to UNLOCK, only one LOCK output will be done.
However, if it maintains unlock after lock output, the corresponding door will not be regarded as fail.
6. The door lock system outputs UNLOCK automatically if the LOCK output conditions are established by this
function or the key is cycled (IGN1=ONOFF) (even when there is no Lock output while the vehicle speed stays
over 50 km/h under lock condition).
However, when the ignition key is turned to OFF position, the lock output conditions will be cancelled.
7. The FAIL condition of the door will be erased when the ignition key is turned to OFF position.
VEHICLE
SPEED
OVER 50 KM/H
BELOW 50 KM/H
LOCK OUTPUT
5 times
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
2C
Auto Door Unlock (Crash Unlock)

For conventional vehicles, G-sensor in RK STICS generates UNLOCK signal when collided over 15 km/h over vehicle
speed. In this vehicle, the factory installed air bag module transmits the collision signal to STICS to unlock the door.
1. The air bag collision signal cannot be accepted within 7 seconds after turning the ignition key to ON position.
2. After this period, the door lock system outputs UNLOCK for all doors for 5 seconds (T2) from 0.4 seconds (T2)
after receiving the air bag collision signal.
3. Even though the key is turned to OFF position during the output of UNLOCK, the output continues on for
remaining period.
4. After input of the air bag collision signal, the door lock system doesnt output UNLOCK even when turning the
ignition key to ON position.
ING SW(*1)
ON
OFF
AIR BAG SIG
ON
OFF
UNLOCK
RELAY
ON
OFF
[Notice]
(1) The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions.
(2) The LOCK/UNLOCK request by other functions will be ignored after/during the output of UNLOCK by the air bag.
However, the door lock is controlled by other functions when IGN1 SW is OFF and IGN2 SW is OFF.
(3) If the door lock system outputs LOCK and UNLOCK simultaneously, only the LOCK output can be activated.
(4) Even though the LOCK/UNLOCK output is requested, the door lock system cannot output LOCK/UNLOCK when all
door lock switches are locked/unlocked.
Also, even though the UNLOCK output for the drivers door is requested, the door lock system cannot output UNLOCK
when the drivers door is unlocked.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
33
12) Time Lag Power Window Control

1. The power window is turned off when turning the ignition key to ON position.
2. The power window relay is turned ON for 90 seconds (T1) when turning the ignition key to OFF position.
However, the power window relay stays on for 90 seconds (T2) when the ignition key is turned to OFF position
while the door is opened.
3. The power window relay is turned ON again for 90 seconds (T2) just for once when opening the door during its
extended operation period of 90 seconds (T1).
4. The power window relay is turned OFF when closing the door during its extended operation period of 90 seconds
(T2).
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
2C
13) REKES (Remote Keyless Entry System)

Transmitter
PANIC function is added on the previous version of REKES.
Door lock button

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

Step 1: Unlocking drivers door
Step 2: Unlocking all doors and tailgate
Panic button: Operates under the theft deterrent

armed mode
Theft deterrent horn: Sounds approx. 27 seconds
CHANGED BY
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AFFECTED VIN
Specification:
CR 2032
Quantity:
1 ea
RK STICS
STAVIC - 2004.09
2C
35
Receiver
1. Operating requirements
- IGN key = OUT (removed)
2. Code registration requirement
- After connecting the B+ to external coding terminal (applying battery voltage)
Transmitter Code Registration

- Only one transmitter code can be registered.
- The received code cannot be output during the registration.
1. Coding terminal: OFF ON (applying battery voltage)
2. Press LOCK, UNLOCK or PANIC switch on the transmitter.
3. Outputs hazard warning flasher for 0.5 seconds (once) and horn for 0.04 seconds (once) during registration.
4. Code output requirements
- The system outputs the function code when the CUSTOM and ID code are correct and the Rolling code is within
operating range while the ignition key is removed and the coding terminal is turned off (grounded).
- Available function code: LOCK / UNLOCK / PANIC
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
36
2C
14) Theft Deterrent

Description of Burglar Alarm Function
1) Armed mode activation requirements
1. The LOCK output is ON when receiving the LOCK signal from transmitter while the ignition key is removed and
all doors are closed. The armed mode is activated when the door lock switch is locked (theft deterrent horn output:
once, hazard relay output: twice).
2. The theft deterrent horn and hazard relay outputs are ON when receiving the LOCK signal from the remote
control key again in armed mode (theft deterrent horn output: once, hazard relay output: twice).
3. When receiving LOCK signal from the remote control key while any of doors is not closed, only the LOCK output
can be done and then activates the armed ready mode (without theft deterrent horn and hazard warning flasher). At
this moment, if the ignition key is in the ignition switch, the door unlock switch is turned ON or the door lock
switch is unlocked (after 0.6 seconds), cancels the armed mode and activates the normal mode. However, in these
cases, if closing the door and locking the door lock switch, the theft deterrent horn outputs once and the hazard
warning flasher outputs twice and then activates armed mode.
4. When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after receiving
UNLOCK signal, outputs LOCK and then activates armed mode (RELOCK operation). Also, at this moment, the
system outputs the theft deterrent horn and hazard warning flasher.
5. The armed mode will not be activated except above conditions.
Ex) The armed mode will not be activated when the door is locked by the ignition key.
Tx SIGNAL
NO SIGNAL
ENTRANCE
DOOR SW
ENTRANCE
DOOR
LOCK SW
OPERATION
ARMED MODE
OTHERS
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
37
2) Armed mode cancellation requirements

1. Unlocking by remote control key or engine starting.
3) Warning operation requirements
1. When opening the door in armed mode
2. When unlocking the door lock switch in armed mode
3. When closing and then opening the door after completion of warning (27 seconds)
4) Warning operation
1. The theft deterrent horn and hazard warning flasher output is ON for T3 (27 seconds) with the interval of T2 (1
second).
5) Warning cancellation requirements
1. Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, START, STOP, PANIC,
CHECK) during warning operation.
2. Cancels warning after 27 seconds (remaining period) while the ignition key is turned to ON position.
6) Operation when warning is cancelled

1. The theft deterrent horn and hazard warning flasher outputs are OFF.
WARNING
REQUIREMENTS
ESTABLISHED
WARNING
CANCELLATION
ESTABLISHED
THEFT
DETERRENT
STATE
WARNING
RK STICS
STAVIC - 2004.09
NO ESTABLISHED
NO ESTABLISHED
ARMED
NORMAL
CHANGED BY
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AFFECTED VIN
38
2C
15) PANIC Warning

1. The PANIC warning output is ON (theft deterrent horn) when receiving the PANIC signal from the remote control
key (pressing PANIC button for less than 0.5 ~ 1.0 second).
2. The PANIC warning output is OFF when receiving any signal from the remote control key during PANIC warning.
3. Followings are theft deterrent warnings:
1) The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft
deterrent.
2) The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC
warning (PANIC output is OFF).
3) The PANIC warning output is ON when receiving the PANIC signal from the remote control key in Armed Ready
/ Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode).
4. This function operates only in armed mode.
5. The system sends the current vehicle conditions (LOCK, engine running) when the PANIC warning is turned off by
the remote control key.
REMOTE
CONTROL KEY
PANIC SIGNAL
THEFT
DETERRENT
WARNING
OTHERS
MODE
HORN
CHANGED BY
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AFFECTED VIN
RK STICS
STAVIC - 2004.09
2C
39
16) Auto Light Function

1. The lights automatically come on and off according to the ambient brightness when the multifunction light switch is
in AUTO position while the ignition key is in ON position.
RK STICS
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
40
2C
7. DIAGNOSIS TROUBLE CODE AND HELP TIPS

The RK STICS and related devices in this vehicle can be diagnosed by SCAN-100.
Diagnostic Procedures
2. Select RK STICS.
Check the part number and version for

installed units
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
1. Select the vehicle model.
3. Select the DTC code.
Sensor data check screen
RK STICS
STAVIC - 2004.09
2C
Code
41
Descriptions
Help
01
Defective auto door lock operation
This DTC is set when the unit didnt receive the contact signal of door
lock actuator after the unit has sent the LOCK signal to the door lock
relay (while the auto door lock is activated and the vehicle speed is
over 50 km/h).
02
Defective door lock relay
lock actuator after the unit has sent the LOCK signal to the door lock
relay by the remote control key or knob.
03
Defective door unlock relay
unlock actuator after the unit has sent the LOCK signal to the door
unlock relay by the remote control key or knob.
04
Defective drivers door unlock

relay
unlock actuator after the unit has sent the LOCK signal to the door
unlock relay by the remote control key. (When the function that opens
drivers door only is not operating)
05
Defective wiper relay
This DTC is set when the wiper stop signal cannot be detected during
the wiper relay operation.
06
Defective INT operation
This DTC is set if the OPEN signal (4 V) is detected when changing

the INT VOLUME value (0 V: FAST, 4 V: SLOW) in vehicle speed
sensitive INT wiper equipped vehicle.
07
Abnormal speed signal
This DTC is set when more than 3 km/h of vehicle speed is detected
from the vehicle speed signal input area while the ignition key is in
ON position and ALT D is LOW.
08
Abnormal air bag collision signal
The air bag unit receives the collision signal.

This DTC is set when the door lock actuator is locked in unlock conditions after the collision signal is entered into collision sensor input end
in air bag unit.
09
Abnormal door ajar warning light

signal
This DTC is set when the door ajar warning light comes on while the
vehicle speed is over 3 km/h.
10
Abnormal air bag collision

sensors input signal
This DTC is set whenever the collision signal is entered into the collision sensor while the ignition key is in OFF position
11
Abnormal air bag collision signal
This DTC is set when the STICS sends the door unlock signal and its
feedback value is normal.
12
Abnormal speed signal
This DTC is set when more than 200 km/h of vehicle speed is detected.
13
Defective parking brake warning

light
This DTC is set when the brake warning light comes on while the
vehicle speed is over 3 km/h.
14
Numbers of auto door lock fault
Maximum numbers: 20 times

The number increases by 1 up to 20 when the fault is detected during
every IGN ON. It is reset to 0 when the DTC code is erased.
15
Numbers of door lock relay fault

16
17
RK STICS
STAVIC - 2004.09
Numbers of door unlock relay

fault
Numbers of drivers door unlock

relay fault

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AFFECTED VIN
42
2C
Removal and Installation of STICS

Preceding Work: Removal of driver side instrument panel undercover
1. Unscrew four bolts and remove the STICS unit.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RK STICS
STAVIC - 2004.09
2D
RAIN SENSING WIPER

The rain sensing wiper unit in this vehicle doesnt control the wiper directly. The rain sensing unit detects the amount of
rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
1. COMPONENTS
Multifunction wiper switch:
AUTO and sensitivity control
Rain sensing unit
AUTO
A sensor that emits infrared rays through LED

and then detects the amount of rain drops by
receiving reflected rays against sensing section
(rain sensor mounting section on the windshield)
with photodiode.
STICS
: Wiper operates automatically by rain sensor

FAST <-------> SLOW
: Auto delay/Auto speed control. A position that

can control sensitivity against rains on the
windshield and transmits wiping demand
signal accordingly.
The rain sensing unit detects the amount of

rain drops and sends the operating signal to
STICS, and STICS drives the wiper directly.
At this moment, STICS determines the wiper
operation mode (washer, MIST, AUTO), then
sends the information to the rain sensor.
RAIN SENSING WIPER

STAVIC - 2004.09
ICM box
The wiper related relays are
installed in ICM box.
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2D
2. RAIN SENSOR OPERATION

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

emitter lens
Unit latch
Emitter lens
Rain sensor
unit
The LED emits the infrared

rays is located at bottom and
the lens guides the infrared
rays to target point.
Housing and
receiver lens
Receiver lens
The receiver lens guides the
reflected infrared rays from
windshield to photodiode.
Housing and PCB
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RAIN SENSING WIPER

STAVIC - 2004.09
2D
3. RAIN SENSOR RELATED CIRCUIT

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

STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
2D
4. OPERATION MODE OF RAIN SENSING WIPER SYSTEM

Switch positions
Operation mode
MIST (Transmits the manual operation
As long as the switch is in MIST position, the wiper motor operates in
mode signal to sensor)
low speed. The wiper blade returns to parking position if the switch
returns to the original position. The rain sensor ignores inputs during
parking signal periods.
OFF (Transmits the manual operation
The wiper motor rotates in low speed until it returns to parking position.
When the system is in manual mode, the sensitivity of sensor will be

set to 2 (AUTO 2) internally. By doing so, immediate wiping with proper
intervals is possible when a driver sets the system from OFF to AUTO.
AUTO 1
SLOW
Auto delay/auto speed control. Low sensitivity against rains on

windshield. When the switch is in AUTO position, the sensor trans-
(Low sensitivity)
mits the wiping request signal to STICS.

AUTO 2
Auto delay/auto speed control.
(Low/medium sensitivity)
Low/medium sensitivity against rains on windshield.
AUTO 3
(Medium sensitivity)
Medium sensitivity against rains on windshield.
AUTO 4
(Medium/High sensitivity)
Medium/high sensitivity against rains on windshield.
AUTO 5
(High sensitivity)
FAST

High sensitivity against rains on windshield.
LOW SPEED (transmits the manual
The wiper motor rotates continuously in low speed of approx. 45 rev./
operation mode signal to sensor)
minute at B+=13.5V. The rain sensor operations are same as in MIST.
HI SPEED (transmits the manual operation
The wiper motor rotates continuously in high speed of approx. 70 rev./
minute at B+=13.5V. The rain sensor operations are same as in MIST.
Washer switch
The washer can be operated as long as the washer switch is pressed.

And, the wiper operates several times as specified. When releasing
the washer switch, the wiper returns back to the parking position. The
STICS transmits the washer signal during its whole washing period
(including dry wiping operation). The rain sensor ignores the rain detection during the washing period.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
RAIN SENSING WIPER

STAVIC - 2004.09
2D
6. DIAGNOSIS PROCEDURES
1. Check the glass and coupler for proper installation.
2. Check the power up function.
3. Check the instant wipe function.
4. Check the washer coupled wiper function.
5. Check the high speed.
6. Find the causes for irregular operations (abrupt operations).
7. Check the system with self-diagnosis function.
RAIN SENSING WIPER

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2D
7. TROUBLESHOOTING
1. The wiper should not operate one cycle when turning the wiper switch to AUTO from OFF position
or Ig S/W (Ig2) while the wiper switch is in AUTO position.
1) When Ig2 with the wiper switch AUTO position, the wiper operates one cycle to remind a driver that the wiper
switch is in AUTO position.
2) When the wiper switch is turned to AUTO from OFF, the wiper operates one cycle. It always operates one cycle
for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining
when turning the wiper switch to AUTO from OFF. However, the wiper operates up to 5 minutes after rain stops.
If this function does not occur, check No. 1 pin. If the pin is normal, check the wiper relay related terminals in ICM
box.
2. It rains but the system does not work in AUTO position.
1) Check whether the wiper switch is in AUTO position.

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

STAVIC - 2004.09
2D
11
5. The wiper responses are too fast or slow.
Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW.
Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper
stage.
RAIN SENSING WIPER

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2D
8. REMOVAL AND INSTALLATION OF RAIN SENSOR

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

STAVIC - 2004.09
2E
INTERIOR SWITCHES
Audio remote control switch
Audio power button

Mode button
SEEK button Up
SEEK button - Down
Mute button
Volume button - Up
Volume button - Down
4WD switch and rear

washer/wiper switch
Outside rearview mirror control

and folding switch
Window switch
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E

(multi-meter integrated type)
Drivers seat warmer switch
Rear fog lamp switch
Front fog lamp switch
Hazard warning flasher switch
Sun roof switch
Multi-meter
Defogger switch
Front room lamp
operation
ESP OFF switch
Front room lamp

operation
Passengers seat
warmer switch
Window switch
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
SWITCHES
1. CENTER SWITCH
Seat Warmer Switch
The seat warmer relay is installed in ICM box and the seat heated wire is installed in the drivers and passengers seat.
When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface
gets 40 5C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified
level.
The is no control switch and unit to control the temperature of the seat surface temperature.
Drivers seat warmer

switch
Seat heated wire (drivers and

passengers seat)
Passengers seat
warmer switch
Seat heated wire (drivers and passengers seat)

in ICM box
Seat heated wire relay - LH
Seat heated wire relay - RH
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
Connector Terminals and Circuit

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

(in ICM box)
[Notice]
The temperature of seat surface should be increased over 20C within 3 minutes after turning on the switch while a person
(height: 175 5 cm, weight: 75 5 kg).
[Notice]
- Do not place anything sharp on the seat.
- When cleaning the seats, do not use organic solvents such as benzene or thinner.
- Do not use this function when the engine is not running. The battery could be discharged.
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
2E
Fog Lamp Switch
Fog lamp
Fog lamp relay

Fog lamp switch
Fog lamp connector
The fog lamp with indicator comes on when pressing the fog lamp switch while the light switch is ON. It goes off
when pressing the switch again.

Fog lamp relay

Engine compartment
fuse and relay box
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
Hazard Warning Flasher Switch

The hazard warning flasher switch is connected to the turn signal lamp circuit. The hazard warning flasher unit is
integrated into the ICM box. If the flasher unit is defective, should replace the ICM box assembly.
Indicator lamp
Flasher unit (in ICM box)
The hazard warning indicators on the indicator display, both turn signal lamps, and both side repeaters blink when
pressing the hazard warning flasher switch.
ICM box
Flasher unit
Left side
lamps
SWITCH
STAVIC - 2004.09
Turn signal lamp

switch
Right side
lamps
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AFFECTED VIN
2E
Defogger Switch
The windshield, tailgate glass, and outside rearview mirrors have heated wire. STICS controls the defogger relay in the
engine room fuse and relay box.
Defogger indicator
STICS
Defogger relay and fuses
Comes on during operation
Controls the heated glass
In the engine compartment
CHANGED BY
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
Circuit Diagram
The defogger switch is connected to STICS. The STICS controls the tailgate windshield and outside rearview mirror
heated glass according to the switch operations while the engine is running.
SWITCH
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2E
Tailgate Heated Glass, Windshield Galss and Outside Rearview Mirror Heated Glass (controlled
by STICS)
1. The outside rearview mirror heated glass operates for 12 minutes when turning on the defogger switch while the
engine is running.
3. If the defogger switch is pressed again within T2 (10 minutes) after completion of the first operation (T1), the
defogger system operates for 6 minutes just for once.
OVER 9 V
BELOW 9 V
T1: 12 min.
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T2: within 10 min.
T3: 6 min.
SWITCH
STAVIC - 2004.09
2E
11
ESPOFF Switch
If the driving wheels are slipping on the snowy or icy road, the engine rpm may not be increased even when depressing
the accelerator pedal, and accordingly, the vehicle may not be started off. In this case, stop the ESP function by
pressing the ESPOFF switch. When the ESPOFF switch is pressed, the ESP function stops and the vehicle is driven
independently from the sensor outputs. However, the ABS function is still activated.
ESP OFF switch
ESPOFF switch and connector
ICM box
ESP indicator and warning light
ESP operation alarm buzzer
When the ESP warning light comes on

The lamp comes on when the vehicle posture control function is cancelled by pressing ESPOFF switch or ESP
related system is defective.
When the ESP warning light blinks and the alarm sounds
It means the ESP function is operating while the vehicle is driving under extremely unstable conditions.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
12
2E
Resuming the ESP function by using ESPOFF switch

The ESP function will be resumed if pressing the ESPOFF switch on the center switch panel again shortly when the ESP
function is cancelled (when the ESP warning light comes on). At this moment, the ESP warning light in the indicator
display goes off and the ESP function is resumed.
[Notice]
- The ESP system deactivates when stopping the engine. It will be resumed when the engine is started again.
- If the vehicle is controlled by ESP during driving, the ESPOFF switch will not work.
- If the ESP warning light comes on, the ESP related system is defective. At this moment, the ABS works in a basic way.
- If the ESP warning light and the ABS warning light come on simultaneously, both ESP and ABS system are not working.
- If the ESP warning light blinks and the alarm sounds, it means that the vehicle stability is controlled by the ESP function
when the vehicle stability is extremely unstable.
- If the ESP function operates while driving, the indicator lamp blinks and the alarm sounds with the interval of 0.1
second.

Rated capacity: DC 12 V, 1 A
CHANGED BY
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
13
Removal and Installation of Center

Switches
front cup holder.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
14
2E
6. Disconnect all switch connectors including TRIP switch connector
during removal of the front cover.
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SWITCH
STAVIC - 2004.09
2E
15
Disconnect the air conditioner connector.
7. Remove the center switch cover and pull out the switches from it.
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
16
2E
4WD SWITCH, REAR WIPER/WASHER SWITCH

1. 4WD (4H 4L) SWITCH: TOD (FULL TIME 4 WHEEL DRIVE)
Driving Mode Change
Driving mode
4H 4L
Changing requirement
Vehicle is stationary.
Selected gear
Neutral
4H (4-Wheel Drive, High) : for driving on normal road

4L (4-Wheel Drive, Low)
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AFFECTED VIN
: for maximum traction needed

in slippery roads, steep hills
and rough roads.

4WD system is defective.
4WD LOW indicator

This indicator blinks during mode changes
(4H 4 L), then goes off after completion.
SWITCH
STAVIC - 2004.09
2E
17
Rear Wiper/Washer Switch
The rear wiper operates with a specific speed when

pressing this switch. It stops when pressing the switch
again.
The washer fluid is sprayed when pressing the switch.

And, the wiper operates when pressing the switch
over 0.6 seconds.

Rated capacity :
wiper - DC 12V, 3.0A

washer - DC 12V, 3.8A
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
18
2E

1. Remove the driver side lower switch panel and remove
the switch bezels.
[Notice]
Be careful not to damage the surroundings during its removal
procedures.
2. Disconnect the connectors and remove the switches.
CHANGED BY
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
19
SWITCHES ON STEERING WHEEL

1. AUDIO REMOTE CONTROL SWITCH
POWER
Turns on and off the audio system.
MODE
Changes the audio mode in order as below:
MUTE
SEEK
SEEK
In radio mode
- Press briefly: Manual searching for a station.
Stops audio output from audio system.

To resume the audio output, press the
button again.
VOLUME
VOLUME
- Press and hold: Automatic searching for a station.

In CD (DVD) player/Cassette tape mode
Increases or decreases the volume.
- Press briefly: Replay next/previous track.

- Press and hold: Move forward/backward in current tract.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
20
2E
2. CIRCUIT DIAGRAM OF AUDIO REMOTE CONTROL SWITCH
Audio
switches
Tail
lamp
relay
Pin number
Descriptions
31
Audio signal
32
Audio ground
33
Tail lamp relay
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
21
Remote control switch on steering

wheel
1. Remove the screws at both sides.
2. Remove the air bag module (horn) from the steering
wheel.
3. Unscrew the bolts and disconnect the remote control switch connector.
4. Remove the remote control switch from the steering wheel.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
22
2E
3. HORN AND THEFT DETERRENT HORN

Horn
Theft Deterrent Horn
CHANGED BY
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
23
4. SWITCHES ON DOOR TRIM

System Components
Outside rearview mirror switch
Outside rearview mirror folding switch

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

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

The operation of power window can be continued for
90 seconds after turning the ignition switch to OFF
position.
Central door locking switch
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
24
2E
2) Switches on Drivers Door
Door lock switch
Window lock switch
Window lock switch
* Abbreviations
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AFFECTED VIN
FLU: Front Left Up
FLD: Front Left Down
FRU: Front Right Up
FRD: Front Right Down
RLU: Rear Left Up
RLD: Rear Left Down
RRU: Rear Right Up
RRD: Rear Right Down
SWITCH
STAVIC - 2004.09
2E
25
2) Circuit Diagram of Switches on Drivers Door
Front Left
Front Right
Rear Left
Rear Right
Door Lock
SWITCH
STAVIC - 2004.09
Front Left Down (FLD)
Front Left Up (FLU)
Front Right Down (FRD)
Front Right Up (FRU)
Rear Left Down (RLD)
Rear Left Up (RLU)
11
Rear Right Down (RRD)
12
Rear Right Up (RRU)
14
LOCK
10
UNLOCK
Illumination
ILL
Power
B+
B+ (S)
13
E(-)
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26
2E
Removal of Outside Rearview Mirror Switch

1. Remove the screws (arrows) from the door trim.
2. Remove the door armrest grip cover and unscrew the screw.
3. Pry off the door lever cover and remove the mounting screws.
4. Remove the door trim.
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
27
5. Unscrew the bolts and remove the door grip from the removed door trim.
6. Unscrew the bolts and remove the outside rearview mirror switch from the door grip.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
28
2E
Removal and Installation of Window Switch

Preceding works: Disconnection of negative battery cable, Removal of door trim
Unscrew the screws and remove the window switch from the removed door trim.
Driver side
Passenger side
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
29
MULTIFUNCTION SWITCH
1. MULTIFUNCTION SWITCH
Steering wheel
Steering wheel
angular sensor
Light switch
Wiper/washer
switch
Specifications
Descriptions
Multifunction
switch
Specifications
Rated voltage
DC 12V
Operating temperature range

Rated load
Light switch
Dimmer and passing switch
Turn signal switch
Wiper switch
-30C ~ +80C
Turn on: 1 A (relay load)
Hi/Low/Passing: 0.3 A (relay load)
6.6 0.5 A (lamp load)
Low: 5 A, Hi: 7 A (motor load)
AUTO: 0.22 0.05 A (relay load)
Fixed: max. 28 A (motor load)
Washer switch
Intermittent wiper switch
MIST switch
SWITCH
STAVIC - 2004.09
4 A (motor load)
Max. 25 mmA
5 A (motor load)
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AFFECTED VIN
30
2E
Multifunction Switch Operating Range
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SWITCH
STAVIC - 2004.09
2E
31
Connector Pins and Designations of Multifunction Switch
Connector A
1. Connector A
Pin number
11
56 7
10
2. Connector A
15
14 16
STAVIC - 2004.09
Descriptions
EB: Dimmer and passing ground
HL: Headlamp low beam
HU: Headlamp high beam
HS(2): Passing switch
TS: Tail lamp switch
HS(1): Headlamp switch
F/AUTO: Rear fog lamp
DEL: Light switch ground
TB: Flasher unit power
10
TL: Turn signal (LH) lamp switch
11
TR: Turn signal (RH) lamp switch
Descriptions
Pin number
22 21 17 20
18 19
SWITCH
Connector B
14
LO: Low wiper speed
15
HI: High wiper speed
16
S: Wiper stop
17
AUTO(W): Intermittent wiper
18
INT(T): Intermittent WIPER
19
BWT: Intermittent power
20
W: Front washer switch
21
BW: Wiper and washer switch
22
MS: Low wiper speed (MIST switch)
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32
2E
Multifunction switch connector

1) Light switch and auto light switch
2) Dimmer and passing switch
3) Turn signal lamp switch
4) Wiper and intermittent switch
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
33
Removal and Installation of Multifunction Switch Assembly

Preceding work: Disconnection of negative battery cable
Cautions
1. Be careful not to drop or shock the air bag module
during removal procedures.
2. Lift up the hook when disconnecting the air bag
contact coil connector.
1. Place the steering wheel to the straight forward direction.

Unscrew the screws at both sides and remove the horn
pad (air bag module).
2. Put an installation mark on the steering wheel and nut and remove the steering wheel.
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
34
2E
3. Remove the driver side instrument lower panel
4. Unscrew the screws from the steering column cover and

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

installation mark and tighten the nut to the
specified tightening torque.
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
35
6. Disconnect the steering wheel angular sensor connector. Unscrew the screws and remove the multifunction switch
assembly.
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
36
2E
2. AUTO LIGHT SENSOR

Overview
The auto light control is a system that turns on/off the tail
lamps and headlamps automatically. The auto light sensor is
installed on the instrument panel (passenger side). This sensor detects the ambient brightness and automatically turns
on and off the tail lamps and headlamps while the light switch
is in AUTO position without light switch operations. The system turns on and off the lamps when passing through the
tunnel during day driving and getting dark due to fog, rain or
snow.
Auto light sensor
Specifications
Description
Auto light sensor unit
Specifications
Operating voltage
Load
9 ~ 16V
Max. 200 mA (relay load)
-30C ~ +85C
Storage temperature
-40C ~ +120C
Location
on instrument panel (passenger side)
Input / Output Circuit Diagram
Headlamp
relay
Tail lamp
relay
Ignition switch
Battery
12V
Control
circuit
Auto light switch
Headlamp
switch
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AFFECTED VIN
Tail lamp
switch
SWITCH
STAVIC - 2004.09
2E
37
Auto Light Sensor Unit Terminals
1. System power supply

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

Switch functions
1. Turn the ignition switch to ON position and turn the multifunction switch in order of OFF tail lamp headlamp
AUTO.
2. Turn on and off the light switch.
3. Turn the light switch to AUTO position. At this moment, the tail lamps and headlamps come on and off automatically
when the brightness of light that reflected on the photodiode in the auto light sensor is the same as voltage that is
set by software in CPU.
4. When operating the tail lamp and headlamp switch manually again, the lamps comes on and off according to the
switch operations not by brightness of light that detected by sensor.
5. When the ignition key is removed, tail lamps and headlamps go off.
Turning on conditions
Lamp
Tail lamp ON condition
Headlamp ON condition
Operation delay time
ON
30.5 5(LUX)
8.9 3(LUX)
0.5 0.1 second
OFF
60.5 5(LUX)
17.2 3(LUX)
3 1 second
Brightness
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
38
2E
Operational Characteristics
IGN SW
Within OFF range
Within ON range
AUTO light SW
Tail lamp
Headlamp
However, the tail lamp and headlamp should be within ON and OFF ranges.
T1: 3 1.0 sec T2: 500 100 msec
Inspection
Position the multifunction switch to AUTO position and cover
the auto light sensor on the instrument panel (passenger side)
with a cloth to block the light coming from outside and then
check the auto light functions.
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
39
WIPER AND WASHER ASSEMBLY

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

washer hose
Wiper motor and

linkage assembly
Washer motor and

washer fluid reservoir
Rear wiper and washer assembly
Washer nozzle and

washer hose
Wiper blade
assembly
Wiper motor and

linkage assembly
Washer motor and
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
40
2E
Specifications
Descriptions
Motor
Specifications
Rated voltage
DC 12 V 0.3 V
Test voltage
DC 13.5 V 0.3 V
DC 10 ~ 15 V
Minimum operating voltage
Below DC 8 V
Over 1 m
Insulating voltage
Restraint test
Torque
Over 1.1 Km
Voltage
Below 14 A
-40C ~ +80C
Surrounding voltage range

Control
DC 12 V
Rated voltage
DC 9 ~ 16 V

-30C ~ +80C
Reserving temperature range
-40C ~ +90C
Over 1 m
Insulating voltage
Below 0.5 V
Voltage drop
(terminals between 5-7, 6-8, 5-8, 6-7 @ 5 A)

14.0 0.5 A
Test voltage
Maximum 10 A
Acceptable load current
Circuit Diagram
Relay 1
Voltage
controller
Relay 2
Wiper motor
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AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
41
2. REMOVAL AND INSTALLATION OF WIPER ASSEMBLY

1. Front Wiper Assembly
Components Locator
Wiper blade
Wiper linkage
Wiper motor
SWITCH
STAVIC - 2004.09
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AFFECTED VIN
42
2E
1. Detach the washer hose

grille.
, unscrew the nut
and remove the wiper blade assembly, and remove the hood cowl
A. Wiper blade assembly
B. Cowl grill
2. Unscrew the bolts
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AFFECTED VIN
and remove the wiper linkage assembly.
SWITCH
STAVIC - 2004.09
2E
3. Disconnect B motor connector
43
. Unscrew two mounting bolts and two nuts and remove the wiper motor.
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
44
2E
2. Rear Wiper Assembly

Preceding work: Disconnection of negative battery cable, removal of tailgate trim
Components Locator
Wiper blade assembly
Rear wiper motor
Rear wiper assembly
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
STAVIC - 2004.09
2E
45
1. Release the wiper arm cap
, remove the wiper nut
2. Disconnect the wiper motor connector

tailgate.
and wiper blade
, unscrew the bolts
, and unscrew the motor lock nut
, and remove the wiper motor assembly from
1. Motor connector
2. Motor mounting bolts
SWITCH
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
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2E
2E - Switch (2005 ~)
Table of Contents
INTERIOR SWITCHES ...................................... 2E-2
SWITCHES ........................................................ 2E-4
1. Center switch .............................................................. 2E-4

......................................................................... 2E-16
1. 4WD switch .............................................................. 2E-16
2. Rear wiper / washer switch ...................................... 2E-17
SWITCHES ON STEERING WHEEL ............... 2E-19

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

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

1. General .................................................................... 2E-39
2. Removal and Installation of wiper assembly ............ 2E-41
SWITCH
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AFFECTED VIN
2E
INTERIOR SWITCHES
Audio power button

Mode button
SEEK button Up
SEEK button - Down
Mute button
Volume button - Up
Volume button - Down
4WD switch and rear

washer/wiper switch
Outside rearview mirror control

and folding switch
Window switch
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EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E

(multi-meter integrated type)
Drivers seat warmer switch
Rear fog lamp switch
Front fog lamp switch
Hazard warning flasher switch
Sun roof switch
Multi-meter
Defogger switch
Front room lamp
operation
ESP OFF switch
Front room lamp

operation
Passengers seat
warmer switch
Window switch
SWITCH
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AFFECTED VIN
2E
SWITCHES
1. CENTER SWITCH
Seat Warmer Switch
The seat warmer relay is installed in ICM box and the seat heated wire is installed in the drivers and passengers seat.
When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface
gets 40 5C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified
level.
The is no control switch and unit to control the temperature of the seat surface temperature.
Drivers seat warmer

switch
Seat heated wire (drivers and

passengers seat)
Passengers seat
warmer switch
Seat heated wire (drivers and passengers seat)

in ICM box
Seat heated wire relay - LH
Seat heated wire relay - RH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E

- Internal circuit diagram of seat warmer switch
Seat warmer relay

(in ICM box)
[Notice]
The temperature of seat surface should be increased over 20C within 3 minutes after turning on the switch while a person
(height: 175 5 cm, weight: 75 5 kg).
[Notice]
- Do not place anything sharp on the seat.
- When cleaning the seats, do not use organic solvents such as benzene or thinner.
- Do not use this function when the engine is not running. The battery could be discharged.
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
Fog Lamp Switch
Fog lamp
Fog lamp relay

Fog lamp switch
Fog lamp connector
The fog lamp with indicator comes on when pressing the fog lamp switch while the light switch is ON. It goes off
when pressing the switch again.

Fog lamp relay

Engine compartment
fuse and relay box
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
Hazard Warning Flasher Switch

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

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

The lamp comes on when the vehicle posture control function is cancelled by pressing ESPOFF switch or ESP
related system is defective.
When the ESP warning light blinks and the alarm sounds
It means the ESP function is operating while the vehicle is driving under extremely unstable conditions.
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2E
Resuming the ESP function by using ESPOFF switch

The ESP function will be resumed if pressing the ESPOFF switch on the center switch panel again shortly when the ESP
function is cancelled (when the ESP warning light comes on). At this moment, the ESP warning light in the indicator
display goes off and the ESP function is resumed.
[Notice]
- The ESP system deactivates when stopping the engine. It will be resumed when the engine is started again.
- If the vehicle is controlled by ESP during driving, the ESPOFF switch will not work.
- If the ESP warning light comes on, the ESP related system is defective. At this moment, the ABS works in a basic way.
- If the ESP warning light and the ABS warning light come on simultaneously, both ESP and ABS system are not working.
- If the ESP warning light blinks and the alarm sounds, it means that the vehicle stability is controlled by the ESP function
when the vehicle stability is extremely unstable.
- If the ESP function operates while driving, the indicator lamp blinks and the alarm sounds with the interval of 0.1
second.

Rated capacity: DC 12 V, 1 A
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
13
Removal and Installation of Center

Switches
front cup holder.
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2E
6. Disconnect all switch connectors including TRIP switch connector
during removal of the front cover.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
15
Disconnect the air conditioner connector.
7. Remove the center switch cover and pull out the switches from it.
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2E

1. 4WD SWITCH
TOD
P/Time
TOD
Driving Mode Change

Type
Driving mode
Requirement
Gear
Vehicle
speed

Part time
TOD
4H 2H 4L
4H 4L

4WD system is defective.
Neutral (A/T), Clutch signal (M/T)
4WD LOW indicator
Stationary

4WD
HIGH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
P/Time
4WD HIGH indicator

SWITCH
2E
17
2. REAR WIPER/WASHER SWITCH
The rear wiper operates with a specific speed when

pressing this switch. It stops when pressing the switch
again.
The washer fluid is sprayed when pressing the switch.

And, the wiper operates when pressing the switch
over 0.6 seconds.

Rated capacity :
wiper - DC 12V, 3.0A

washer - DC 12V, 3.8A
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
2E

1. Remove the driver side lower switch panel and remove
the switch bezels.
[Notice]
Be careful not to damage the surroundings during its removal
procedures.
2. Disconnect the connectors and remove the switches.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
19
SWITCHES ON STEERING WHEEL

1. AUDIO REMOTE CONTROL SWITCH
POWER
Turns on and off the audio system.
MODE
Changes the audio mode in order as below:
MUTE
SEEK
SEEK
In radio mode
- Press briefly: Manual searching for a station.
Stops audio output from audio system.

To resume the audio output, press the
button again.
VOLUME
VOLUME
- Press and hold: Automatic searching for a station.

In CD (DVD) player/Cassette tape mode
Increases or decreases the volume.
- Press briefly: Replay next/previous track.

- Press and hold: Move forward/backward in current tract.
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
2E
POWER ON/OFF
2. CIRCUIT DIAGRAM OF AUDIO REMOTE CONTROL SWITCH
Audio
switches
Tail
lamp
relay
Pin number
Descriptions
31
Audio signal
32
Audio ground
33
Tail lamp relay
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
21
Remote control switch on steering

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

Horn
Theft Deterrent Horn
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
23
4. SWITCHES ON DOOR TRIM

System Components
Outside rearview mirror switch
Outside rearview mirror folding switch

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

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

The operation of power window can be continued for
30 seconds after turning the ignition switch to OFF
position.
Central door locking switch
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
2E
1) Switches on Drivers Door
Door lock switch
Window lock switch
Window lock switch
* Abbreviations
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FLU: Front Left Up
FLD: Front Left Down
FRU: Front Right Up
FRD: Front Right Down
RLU: Rear Left Up
RLD: Rear Left Down
RRU: Rear Right Up
RRD: Rear Right Down
SWITCH
2E
25
2) Circuit Diagram of Switches on Drivers Door
Front Left
Front Right
Rear Left
Rear Right
Door Lock
SWITCH
Front Left Down (FLD)
Front Left Up (FLU)
Front Right Down (FRD)
Front Right Up (FRU)
Rear Left Down (RLD)
Rear Left Up (RLU)
11
Rear Right Down (RRD)
12
Rear Right Up (RRU)
14
LOCK
10
UNLOCK
Illumination
ILL
Power
B+
B+ (S)
13
E(-)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2E
Removal of Outside Rearview Mirror Switch

1. Remove the screws (arrows) from the door trim.
2. Remove the door armrest grip cover and unscrew the screw.
3. Pry off the door lever cover and remove the mounting screws.
4. Remove the door trim.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
27
5. Unscrew the bolts and remove the door grip from the removed door trim.
6. Unscrew the bolts and remove the outside rearview mirror switch from the door grip.
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
2E
Removal and Installation of Window Switch

Preceding works: Disconnection of negative battery cable, Removal of door trim
Unscrew the screws and remove the window switch from the removed door trim.
Driver side
Switch
Passenger side
Switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
29
MULTIFUNCTION SWITCH
1. MULTIFUNCTION SWITCH
Steering wheel
Steering wheel
angular sensor
Light switch
Wiper/washer
switch
Specifications
Descriptions
Multifunction
switch
Specifications
Rated voltage
DC 12V

Rated load
Light switch
Dimmer and passing switch
Turn signal switch
Wiper switch
-30C ~ +80C
Turn on: 1 A (relay load)
Hi/Low/Passing: 0.3 A (relay load)
6.6 0.5 A (lamp load)
Low: 5 A, Hi: 7 A (motor load)
AUTO: 0.22 0.05 A (relay load)
Fixed: max. 28 A (motor load)
Washer switch
Intermittent wiper switch
MIST switch
SWITCH
4 A (motor load)
Max. 25 mmA
5 A (motor load)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
2E
Multifunction Switch Operating Range
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
31
Connector Pins and Designations of Multifunction Switch
Connector A
1. Connector A
Pin number
11
56 7
10
2. Connector A
15
14 16
Descriptions
EB: Dimmer and passing ground
HL: Headlamp low beam
HU: Headlamp high beam
HS(2): Passing switch
TS: Tail lamp switch
HS(1): Headlamp switch
F/AUTO: Rear fog lamp
DEL: Light switch ground
TB: Flasher unit power
10
TL: Turn signal (LH) lamp switch
11
TR: Turn signal (RH) lamp switch
Descriptions
Pin number
22 21 17 20
18 19
SWITCH
Connector B
14
LO: Low wiper speed
15
HI: High wiper speed
16
S: Wiper stop
17
AUTO(W): Intermittent wiper
18
INT(T): Intermittent WIPER
19
BWT: Intermittent power
20
W: Front washer switch
21
BW: Wiper and washer switch
22
MS: Low wiper speed (MIST switch)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2E
39
WIPER AND WASHER ASSEMBLY

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

washer hose
Wiper motor and

linkage assembly
Washer motor and

Rear wiper and washer assembly
Washer nozzle and

washer hose
Wiper blade
assembly
Wiper motor and

linkage assembly
Washer motor and
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
40
2E
Specifications
Descriptions
Motor
Specifications
Rated voltage
DC 12 V 0.3 V
Test voltage
DC 13.5 V 0.3 V
DC 10 ~ 15 V
Minimum operating voltage
Below DC 8 V
Over 1 m
Insulating voltage
Restraint test
Torque
Over 1.1 Km
Voltage
Below 14 A
-40C ~ +80C
Surrounding voltage range

Control
DC 12 V
Rated voltage
DC 9 ~ 16 V

-30C ~ +80C
Reserving temperature range
-40C ~ +90C
Over 1 m
Insulating voltage
Below 0.5 V
Voltage drop
(terminals between 5-7, 6-8, 5-8, 6-7 @ 5 A)

14.0 0.5 A
Test voltage
Maximum 10 A
Acceptable load current
Circuit Diagram
Relay 1
Voltage
controller
Relay 2
Wiper motor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
41
2. REMOVAL AND INSTALLATION OF WIPER ASSEMBLY

1. Front Wiper Assembly
Components Locator
Wiper blade
Wiper linkage
Wiper motor
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
42
2E
1. Detach the washer hose

grille.
, unscrew the nut
and remove the wiper blade assembly, and remove the hood cowl
A. Wiper blade assembly
B. Cowl grill
2. Unscrew the bolts
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
and remove the wiper linkage assembly.
SWITCH
2E
3. Disconnect B motor connector
43
. Unscrew two mounting bolts and two nuts and remove the wiper motor.
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
44
2E
2. Rear Wiper Assembly

Preceding work: Disconnection of negative battery cable, removal of tailgate trim
Components Locator
Wiper blade assembly
Rear wiper motor
Rear wiper assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
SWITCH
2E
1. Release the wiper arm cap
45
, remove the wiper nut
2. Disconnect the wiper motor connector

tailgate.
and wiper blade
, unscrew the bolts
, and unscrew the motor lock nut
, and remove the wiper motor assembly from
1. Motor connector
2. Motor mounting bolts
SWITCH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2F
MULTI-METER
1. LOCATION
1. MODE button - Mode change and reset

Selects a mode (altitude, direction, time, calendar, average speed, driving time, battery)
2. UP button - coupled operation with MODE button
Increases the value (altitude, direction, date, atmospheric pressure) in each mode.
3. DOWN button - coupled operation with MODE button

Decreases the value (altitude, direction, date, atmospheric pressure) in each mode.
4. Display
Displays a selected mode screen, parking aid signal, and battery voltage message.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2F
2. CIRCUIT DIAGRAM
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
3. DISPLAY MODE
Mode changing sequence:
[Time and Calendar]
[Altitude, Direction]
[Driving time]
[Battery voltage]
[Average speed]
[Note]
The previously selected

mode screen appears
when starting the engine.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2F
4. FUNCTIONS IN EACH MODE

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

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

4. Press and hold the MODE button for more than 1 second to set the time and date.
[Note]
- A day of the week is automatically changed according to the adjusted date, month, and year.
- An intercalary is automatically calculated.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
2) Direction, Atmospheric Pressure, Altitude Mode

Electronic Compass
It indicates 8-direction by interval of 45 according to the vehicles driving direction.
1. Screen display for direction

Display
Direction
NE
45
90
SE
135
180
SW
225
270
NW
315
[Note]
This function is available only when the vehicle speed is over 2.8 km/h.
2. Turning Calibration
This operation is needed to calibrate the indication tolerance between the actual direction and the indicated direction
at current vehicle location.
Turning calibration conditions
- when the multi-meter is installed in the vehicle.
- when the battery is replaced.
Turning calibration procedure
1. When pressing the MODE and UP button simultaneously for more than 1 second, the current direction flashes.
2. Turn the vehicle over 1 complete circle within 128 seconds slowly, then the calibration will be accomplished.
3. When the calibration is finished, the vehicles new direction will be indicated.
[Note]
The turning calibration process is automatically canceled if the vehicle is not turned within 120 seconds after calibration
mode started.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2F
Altimeter
1. Absolute Altimeter
0 m above the sea level is equivalent to 1013.25 hpa and the altimeter convert the difference between this pressure and
atmospheric pressure to absolute altitude. Its Indication range is -200 m to 2,800 m.
Current atmospheric pressure
Current altitude
How to calibrate the absolute altitude

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

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

It can be calibrated by 300 m within the range of 0 to 2,800 m.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
2. Relative Altimeter
It indicates the specific areas relative altitude based on the current altitude of the vehicle (current altitude is indicated
to 0 m).
Indication of relative altimeter
Indication of base altitude
Changing to relative altimeter mode

The mode is switched between the relative altimeter mode and absolute altimeter mode when pressing the MODE
button over 1 second in direction/atmospheric pressure/altitude mode.
Barometer
It indicates the current atmospheric pressure in range from 720 hpa to 1045 hpa by 1 hpa.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2F
3) Speed Sensing Indicator

The flashing interval of the road signs changes gradually according to the vehicle speed.
Flashing interval according to the vehicle speed

Vehicle speed
Flashing interval
below 1.8 km/h
stays ON
below 40 km/h
1 second
below 60 km/h
0.8 seconds
below 80 km/h
0.5 seconds
below 100 km/h
0.3 seconds
over 100 km/h
0.2 seconds
4) Driving Time
- It indicates the driving time from start up to now.
- It can be reset to 0 when turning the ignition key to OFF
position or pressing UP or DOWN button for a specific
period of time.
- Indication range: 0:00 ~ 23:59
5) Average Speed
- It indicates the average vehicle speed from start up to
now.
- It can be reset to 0 km/h when turning the ignition key to
OFF position or pressing UP or DOWN button for a
specific period of time.
- Indication range: 0 ~ 120 km/h
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
11
6) Parking Aid Signal Mode

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

parking aid sensor is defective.
[Note]
The display returns back to previous mode screen when
placing the selector lever to other positions.
Display changes according to the distance between rear bumper and rear obstacle
Rear left sensor
Rear center
Rear right
sensor
sensor
Detecting obstacle at rear
Detecting obstacle at rear right
left of the vehicle
center of the vehicle
right of the vehicle
and rear center of the vehicle
All displaying bars are displayed when the distance between rear bumper and obstacle is over 120 cm.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches.
MULTIMETER
STAVIC - 2004.09
Step
Distance
Step 1
80 ~ 120 cm
Step 2
50 ~ 80 cm
Step 3
below 50 cm
Alarm interval (msec)
Display
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2F
7) Battery Mode
- The screen shows fully charged battery when the battery voltage is over 12 V.
- It indicates the current battery voltage by 0.1 V.
- When the battery voltage goes below 9 V, current display is changed to battery voltage mode and LOW VOLTAGE
message flashes.
Charging level
Battery voltabe
Charging Level
Battery voltage
Indication
Over 12.0 V
(fully charged)
11.9 ~ 11.0 V
10.9 ~ 10.0 V
9.9 ~ 9.0 V
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MULTIMETER
STAVIC - 2004.09
2F
13

1. Open the sunglasses box, remove two screws from the
box, and pry off the overhead console with a flat blade
screwdriver.
2. Disconnect the multi-meter connector and the room lamp

connector and remove the overhead console.
3. Unscrew three screws from the back of the overhead console and remove the multi-meter.
MULTIMETER
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2G
AV SYSTEM
1-DIN head unit equipped with cassette deck and radio is installed as a factory installed item and 2-DIN head unit
equipped with extra CD player (with MP3) and equalizer is installed as an optional item. There are 6 speakers in basic
and it can be 12 including tweeter if equipped with DVD system.
6-CD changer and 8-DVD changer can be installed as an extra item. DVD changer is available for the vehicle equipped
with DVD head unit and can play audio CD, video CD, MP3 CD and DVD CD.
Followings are AV systems and will be described based on the vehicle equipped with DVD system.
1. AV SYSTEM BY VEHICLE MODEL

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

switch on steering wheel
DVD head unit + Navigation + DVD changer

Subwoofer with built-in amplifier
Tweeter
Front door speaker
Rear speaker
DVD changer
TV antenna module
Radio antenna module
GPS antenna
AV head unit
Rearview camera
Rear monitor
(DVD)
Front center speaker

Rear center
on steering wheel
tweeter
Rear center
speaker
Amplifier/tuner/navigation unit
with built-in DSP function
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
2G
2. SYSTEM LAYOUT (BASED ON DVD EQUIPPED SYSTEM)

Tweeter speaker
Tweeter speaker
Center speaker
Center speaker
AV head unit
Audio remote
control switch
Front speaker (RH)
Front tweeter
speaker (RH)
GPS antenna
Subwoofer with
built-in amplifier
Center speaker
(RH)
AV head unit
DVD changer
Center speaker
(LH)
Front tweeter
speaker (LH)
Front speaker (LH)
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
Center speake
2G
DVD changer
Rear speaker (RH)
Radio antenna amplifier

Rearview camera
er
Rear monitor
Tuner/amplifier/navigation unit
Rear speaker (LH)
Tuner
Amplifier with built-in

DSP function
Navigation unit
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
2G
3. DVD SYSTEM SIGNALS AND DATA PROCESSING
DVD changer
Rearview camera
It is installed in the center console. Audio signal of

DVD changer outputs to corresponding speakers
through optical fiber cable. Video signal is transmitted to the monitor of AV head unit and rear monitor.
Even though the AV head unit is turned off, the rearview display always appears when placing the gear
selector lever to R position. The reverse driving
signal is prior to all other video signals.
Send
Optical fiber cable
Receive
Tuner
TV sound (TV antenna, LH)
TV sound (TV antenna, RH)
Send
TV video data
Sound communication line
(Bus line)
AV head unit
(with built-in EGA 6.5 monitor)
AM/FM radio antenna AMP

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

The glass antennas at both rear quarter glasses
are to receive TV and AM radio (quarter RH
glass) signals and transmits each 2-channel
video and audio signals to tuner. Each AMP
amplifies receives TV signals and then transmits to tuner.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
Navigation (DVD data)

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

A device that receives and transmits current vehicle
position from and to GPS satellite to display the vehicle position on the map as dot.
Audio signal
Front speaker (LH)
Video signal
Tweeter speaker (LH)
Front speaker (RH)

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

Receive
Rear speaker (RH)
AMP (with built-in DSP)

Power AMP in the DVD system has built-in
DSP function that digitalizes sound to divide
and control. It amplifies sound goes to each
speaker and has function of allowing dynamic
and vivid sound.
Tweeter speaker (RH)
Center speaker (LH)
Center speaker (RH)

Center speaker
(back of center console)
Rear monitor
Video signal
Subwoofer (with built-in AMP)
The rear monitor (7) can be folded down approx. 25

when the open button is pressed to display. When opened,
the angle can be adjusted up to 100 manually.
Woofer with built-in amplifier is installed at

the bottom of passengers seat. It enforces
mid-low sounds and the amplifier built-in the
woofer amplifies sound signal received from
power AMP directly.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
2G
4. SYSTEM LAYOUT (BASED ON DVD SYSTEM)

1) Front Head Unit
Functions
The AV head unit equipped with DVD system has two optical output terminals; one is to receive the sound signal from 8DVD changer and the other is to send the sound signal to amplifier with built-in DSP. The tuner unit transmits the TV and
video signals to the head unit through cable. However, the head unit receives the video signal or color and video signal
directly from the rearview camera and navigation without tuner.
If equipped with roof monitor, the AV head unit transmits the video signal to roof monitor through cable.
[Notice]
The DVD system drives the amplifier, tuner, head unit and 12 speakers and operates two monitors. Therefore, the battery
can be discharged easily if operate DVD system without engine running.
DVD NAVI
Rearview camera
Audio signal
(Video signal)
AV head unit
AVC-LAN
(EGA/6.5)
Roof monitor (7)
DVD changer
OPTIC
TX
OPTIC
TX
Optical fiber cable
Optical fiber cable
(Video signal)
Tuner unit
OPTIC
RX
5.1 channel
power amplifier
OPTIC
RX
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
Appearance
Front view of head unit
Touch-screen panel
When cleaning the touch screen, turn off the system and clean
the surface with a dry and soft cloth. Never use any coarse
cloth, hard cloth, chemical agent, volatile cleaning solvent
(alcohol, benzene, thinner) for cleaning the touch screen.
[Notice]
Do not apply excessive force to adjust, open, and close the monitor. Do not impede the automatic
movement of the unit.
When removing LCD monitor

DVD deck
Tape deck
Reset button
Forceful operation or impeding the
movement of AV system may
cause unstable operations. When
the system operation is unstable,
push the reset button with a sharp
object like a ball-point pen to initialize the system.
Rear view of head unit
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
10
2G
Usable Discs (DVD Head Unit)

Following disc types can be used on the system.
Disc type and logo
Disc size
Play time
approx. 133 minutes (SS/SL)
approx. 242 minutes (SS/DL)
DVD video
approx. 266 minutes (SD/SL)

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

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

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

When playing the double layer disc, there occurs time lag between at the end of first layer and start of second layer
causing broken display and sound for seconds. It normal for double layer disc so it is not malfunction of the system.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
11
Head Unit Operation Buttons

POWER
Turns ON/OFF AV system.
Available while the ignition key is in ACC or
ON position.
NAVI (CURRENT LOCATION)

This button is used for changing Mode in AV
mode. In NAVI screen, this button is used for
displaying the current location.
MODE
Changes AV mode and turns on/off the Mode
display with Power ON. The display returns back
to previous screen when pressing Mode button
over 2 seconds in NAVI mode.
VOL
DESTINATION
This button is used for setting
Destination in NAVI mode.
Volume Up/Down
MENU
AV MODE: Controls the display, tone and
menu with Power ON.
NAVI MODE: Displays menus in NAVI
mode.
To control the display, volume and others,
press and hold the button for over 2
seconds.
OPEN / CLOSE
Moves the monitor to fully open or close position.
When pressing this button, the monitor moves to
fully open position if it is not in fully open position,
and moves to previously stored tilting position if it
is in fully open position.
TILT
Moves the monitor to desired tilting position while
pushing this button.
UP button is not available when the fully close
position.
The down tilting angle can be precisely adjusted by
using Down button within a specified range. If it
reaches to its end, no more movement can be done.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
12
2G
Descriptions of Terminals
Connector A (26-pin)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
BUS 1 output
BUS 1 input
BUS 1 ground
TV LHTV RHRemote control ground
S-Remote control
V-ground
TV-Video
IlluminationReverse signal
ACC+
Battery+
BUS 2 output
BUS 2 input
BUS 2 ground
TV LH+
TV RH+
Ground
R-Remote control
Remote control ground
VSYNC
Illumination +
Parking signal
Ground
Speed pulse
Connector B (20-pin)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
M. Ground
Rearview camera battery output
Rearview camera Vground
Rearview camera video
Navigation voice
Navigation Vground
Navigation CSYNC
Navigation Gi
Remote control optic sensor ground
Remote control optic sensor signal
Amp mute
Amp ON
Amp voice ON
Amp ground
Navigation voice output
Navigation voice ON
Navigation voice BI
Navigation GI
Connector C (16-pin)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
RVSYNC
RSYNC
Vground
R-G
RGB ground
R-Mode 1
Ground
Mute
Video
Power ON
N.C.
R-SSW
R-B
R-R
R-Mode 2
-
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
13
Specifications
System
Radio/TV
Function
- Manual preset: FM1 (6), FM2 (6), AM (6), TV1 (6), TV2 (6)
- Manual channel up/down
- Seek up/down
- BSM (AM/FM), auto memory (TV)
- Local/DX (use with BSM: -20db)
Tape
- Program/Play
- FF (fast forwarding)/REW (rewinding)
- DOLBY B-NR
- AUTO METAL
- Repeat
- Back-up eject function
- Auto power when tape is inserted
DVD player
- Chapter, file, track up/down, direct

- FF (fast forwarding), FB (fast back), up/down
- Repeat
- PBC
- SCAN
- Compatible conversion between audio and caption
- MP3 file information display
- CD-DA, video CD, DVD audio, DVD video, MP3
Key input
- Touch screen: touch panel

* Displays keys by each mode
- Front key: Potential difference type
* POWER, MODE, MENU
* Eject, slide up/down
* NAVI, Destination
* Volume up/down
- NAVI mode: NAVI graphic video switch shift
NAVI display
- Touch screen key: full touch
Display OFF
- If the display disturbs the driving conditions at night, possible to turn off just display.
- Cancellation of display OFF
* Screen touching
* Power key input
* NAVI key input
* MODE and MENU key input
Audio OFF
- Operates only in NAVI mode

* Performs mute under AM, FM, TV, TAPE, DVD, DVDC mode
* Under TAPE mode, deck operation stops
* Under DVD changer and DVD player mode, it stops
Sliding memory
- Sliding memory setting

* Set the desired position with slide up/down key
- Returning to slide position
* Open key input under full-open state
* When changing ACC OFF to ON, moves to the latest stored position
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
14
2G
Function Settings on Touch Panel (Example)

DSP control
* STADIUM: Turns off EQ mode and changes to STADIUM

* HALL: Turns off EQ mode and changes to HALL
* CHURCH: Turns off EQ mode and changes to CHURCH
* CLUB: Turns off EQ mode and changes to CLUB
* OFF: Turns off DSP mode and changes to EQ mode
* Finish: Changes to start page of each mode.
* Previous: Changes to basic control display
EQ control
* DEFEAT: Changes to DEFEAT in EQ mode

* CLASSIC: Changes to CLASSIC in EQ mode
* JAZZ: Changes to JAZZ in EQ mode
* ROCK: Changes to ROCK in EQ mode
*
: Up/down in selected band
* Finish: Changes to start page of each mode

FADER, BALANCE control

*
: Up/down in FADER/BALANCE
* Available in DSP OFF

* Finish: Changes to start page of each mode
POSITION control
* POS: Changes in order of ALL F/R F/L REAR ALL
* Finish: Changes to start page of each mode.
* Can control if in DSP ON
DVDC DISC input

DVDC DISC input display
* 1~8: DISC selection
* Finish: Moves to normal video display
* Previous: Changes to basic 1 display of DVDC DVD OSD
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
15
Terms on DVD System

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

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

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

Audio source is digitalized and can set the atmosphere proper for the place. AV system on STAVIC has 4 fields STADIUM, HALL, CHURCH and CLUB.
DTS-DVD
Recently, it is using as music format for DVD titles. Dolby Digital or PCM type is poplar for DVD-VIDEO, but DTS
function is increasing for high-end AMP or players. In case of DTS, level of sound division and every details are recorded
(DVD title) and has 1/3 of compression ratio compared with Dolby Digital 5.1. So a title, having large capacity, that
formatted by DTS function cannot record other supplement and subtitles.
However, it is very sensitive to sound so people accustomed to 5.1 channel prefer DTS titles.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
16
2G
2) Tuner / 5.1 Channel AMP with Built-in DSP / DVD Navigation

(DVD System Basic)
Tuner, AMP and navigation units are installed together at bottom of driver side rear quarter door panel. Remove the lower
quarter trim panel to replace the units.
Tuner
A tuner filters and cuts unnecessary signals among
received signals and then precisely adjusts input
signals. Installed tuner has following functions.
Connecting terminal of the tuner receives amplified
signals from each TV antenna module locating rear
quarter glass that receives TV signals from glass
antenna and then inputs to left and right channel.
AM/FM radio module on the roof panel rear end receives amplified signals from glass antenna and then
transmits to tuner input (1 channel).
TV antenna module RH
TV antenna module LH
2 channels
2 channels
Radio antenna module
DVD Navigation
Navigation unit in this vehicle transmits huge amount of data on the
DVD CD directly to AV head unit, without via tuner and AMP. It has
3D view function for roads and buildings and supporting data. GPS
antenna to receive/send vehicle position from/to satellite is located
behind the Instrument panel.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
17
5.1 channel power amplifier with built-in DSP

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

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

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

(AV head unit)
Connector
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
18
2G
3) Rear Monitor (Roof Monitor)

Location
The size of rear monitor is 7 inch. When pressing the OPEN button, the power is supplied and the rear monitor slide
down by approx. 25. After then, manually adjust the monitor to desired angle. Its angle can be adjusted by 100.
Rear monitor
Front monitor
Monitor Control
Rear monitor Brightness / Tint / Color control dial
OPEN switch
When pressing the OPEN button, the power is supplied and the rear monitor slide down by approx. 25.
OPEN switch (Power supply button)
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
19
Location
Opening angle
When pressing the OPEN button, the power is supplied and the rear monitor slide down by approx. 25. After then,
manually adjust the monitor to desired angle. Its angle can be adjusted by 100.
Press OPEN (approx. 25)
Maximum opening angle (approx. 100 )
Remote controller for rear monitor

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

When moving the gear selector lever into R (Reverse) position while watching DVD or VCD, the rearview appears on the
front monitor but the rear monitor continues to show the current screen.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
20
2G
5. REMOVAL AND INSTALLATION

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

2. Disconnect the connectors and optical fiber cables from the back of the head unit.
[Note]
The unit with DVD changer has two optical fiber cables and the unit without it has one optical fiber cable.
3. Remove the AV head unit assembly.

CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
21
Tuner
1. Disconnect four TV antenna terminals, main connector
and radio antenna connector.
Main connector
TV antenna
Radio antenna
2. Unscrew eight bolts and remove the deck.

3. Unscrew bolts and remove the tuner unit.
[Tuner unit]
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
22
2G
Amplifier with Built-in DSP

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

2. Unscrew bolts (3 x 2) at front and rear sides and remove the amplifier.
DVD Navigation
Preceding work: Removal of Tuner/Amplifier deck
Unscrew the bracket bolts (2 x 2), disconnect the rear amplifier connector, and remove the navigation unit.
[Notice]
Make sure to remove the tuner/amplifier deck before
disconnecting the connector.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
23
Rear Monitor
1. Unscrew four fixing bolts (10 mm) with the rear monitor
lowered.
2. Disconnect the connector and remove the rear monitor assembly.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
24
2G
Subwoofer Speaker
Preceding work: Removal of passengers seat
Remove four bracket bolts and disconnect the connector and terminals.
Front Door Speaker
Refer to Body section.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
25
Rear Door Tweeter Speaker
1. Remove the rear door trim.
2. Disconnect the connector from the door trim.
3. Unscrew the bolts from the removed door trim and remove the tweeter speaker.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
26
2G
Rear Quarter Speaker

Preceding work: Removal of passengers seat
1. Remove the rear lower quarter panel.
2. Disconnect the connector A from the rear quarter

speaker.
3. Unscrew the screws and remove the rear quarter speaker.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
27
Front Center Speaker
1. Separate the front center speaker as shown in

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

speaker assembly.
3. Unscrew the screws from the removed front center speaker assembly and remove the front center
speaker.
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
28
2G
Front Tweeter Speaker
1. Remove the instrument panel.
2. Disconnect the tweeter speaker connector from the removed instrument panel, unscrew the screws and
remove the tweeter speaker.
CHANGED BY
AV SYSTEM
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2G
29
TV Antenna Module (LH/RH)
Radio Antenna Module
Preceding work: Removal of rear quarter upper

panel
Preceding works:
Removal of luggage room lamp,Removal of third
and fourth row seats, Removal of rear quarter upper
and lower trims, Removal of rear headlining
1
TV antenna connections
Radio antenna connection
AV SYSTEM
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
MEMO
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2H
COMPONENTS OF PARKING AID SYSTEM

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

When moving the gear selector lever into R (Reverse) position while watching DVD or VCD, the rearview appears on the
front monitor but the rear monitor continuously shows current screen.
Multi-meter
Front monitor
ICM box
Even in other modes, it is changed to the parking

aid screen when moving the gear selector lever into
R position.
When moving the gear selector lever into

R position while watching DVD or VCD,
the rearview appears on the front monitor.
When moving the gear selector lever into R

position, the alarm buzzer in ICM box sounds
(installed at bottom of STICS).
Rearview camera
When selecting R position while A/V system is in use:
The video mode in front A/V system is changed to rearview monitoring mode. However, the audio mode stays on.
The video mode in front A/V system resumes when
shifting out from R position.
The audio and video mode in rear A/V system are not
changed.
When selecting R position while A/V system is not in use:
Both monitors are automatically turned on to display rearview.
Both monitors are automatically turned off when shifting
out from R position.
Gear selector lever

(R position)
Applies power to parking aid system.
Parking aid sensor

(Rear bumper)
Rearview camera
The three parking aid sensors send the distance

data between rear bumper and obstacle to PAS
unit.
The rearview camera sends the rearview to the monitor by using wide angle
lens.
PAS unit
It is a control unit for the parking aid system (PAS)

and transmits the signals from sensors to multimeter and buzzer.
(installed in tuner/amplifier bracket)
PARKING ASSISTANCE SYSTEM

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
2. SYSTEM CONTROL
Parking Aid Unit
Send
Generates sensor
12 V
driving signals
Back
Regulator
sonar
Signal transmitter
AMP
& BPF
GND
Receive
Parking Aid Sensor
Reverse driving
(supplies power)
Buzzer
(ICM box)
Back sonar
sensor
(LH)
Back sonar
sensor
(Center)
Back sonar
sensor
(RH)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2H
3. PARKING AID SYSTEM (PAS)

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

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

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
4. COMPONENT SPECIFICATIONS
The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval
and detects the reflected signals from obstacles while the gear selector lever is in R position.
The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches. This
supplementary system is to secure the safety distance for parking.
Descriptions
Value
Value
-30C ~ +80C
DC 9 V ~ 16 V
Storage temperature
-40C ~ +85C
Unit
Below 100 mA
Relative humidity
Sensor
Below 20 mA (each)
Rated voltage
DC 12 V
Operating voltage
Current
consumption
Descriptions
Sensor insulating resistance
Weight
Over 5 M
95%RH max
Unit
160g 10g max
Sensor
70g 10g max
1) Parking aid unit

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

- Type: Piezo ceramic element
- Frequency: 40 KHz 2 KHz
- Detecting range (13.5 V)
* Horizontal: Min. 20 at 110 5 cm
Min. 100 at 50 5 cm
* Vertical: Min. 20 at 110 5 cm
Min. 60 at 50 5 cm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2H
3) Alarm interval
Alarm interval and display changes according to the distance as below:
While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the
warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously.
Stage
L, C, R sensor
Interval (msec)
Remark
65
65
1
81 ~ 120 cm
Beep
195
195
65
65
2
65
65
Beep
Beep
Beep
51 ~ 80 cm
25 ~ 50 cm
Beep
Troubleshooting of Sensor
When the power is applied (gear selector lever is in R position), the sensor will be diagnosed once. If found any failure
due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on failed
sensor transmits to the instrument panel to light up the corresponding LED. If normal, the warning buzzer sounds only
for 65 ms.
1) Whenever the power is applied, the diagnosis mode is initiated.
2) Sensor failure conditions (conditions for warning beep due to failure)
(a) Sensor failure conditions (conditions for warning beep due to failure)
(b) Open in sending circuit
(c) Open in receiving circuit
(d) Open in power circuit (+, -)
Back sonar (RH)
Back sonar (LH)

Back sonar (center)
* Warning beeps
300ms
300ms
When failed
65ms
65ms
When normal

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2H
4) Cautions on parking aid system
* Note that the display does not show everything in the rear area.
Always check nobody, especially animals and children, is behind the vehicle.
* Normal precautions when reversing should be maintained.
1. The parking aid system is just a supplemental device to help your parking operation.
2. Always keep the safety precautions.
3. Do not press or shock the sensors by hitting or high-pressure water gun while washing, or the sensors will be
damaged.
4. If the system is in normal operating conditions, a short beep sounds when the gear selector lever is moved into R
position with the ignition key ON.
5. If the system is in abnormal operating conditions, a beep sounds for 3 seconds when the gear selector lever is
moved into R position with the ignition key ON or engine running. However, it is also occurred when the obstacle
is within 50 cm from the rear bumper.
The parking aid system will not work or improperly work under following cases:
1) Certain obstacles that sensors can not detect
- Wires, ropes, chains.
- Cotton, sponge, clothes, snow that absorb ultrasonic waves.
- Obstacles lower than the bumper.
2) Not defective but improperly working
- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
3) Narrowed sensing area
- When the sensing portion is partially covered by snow or mud.
- Surrounding temperature of sensor is too high (approx. over 80C) or too low (approx. below -30C)
4) Not defective but may occur improper working
- When driving on the rough roads, gravel road, hill and grass.
- When the bumper height is changed due to the heavy load.
- When the sensing portion is frozen.
- When the sensing portion is covered by rain, water drops, snow or mud.
- When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles).
- When a high-power radio is turned on.
- When some accessories are attached in detecting ranges
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2H
5) Circuit Diagram

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2H

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

STAVIC - 2004.09
2H
11
Parking Aid Unit

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

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2H
REARVIEW CAMERA
This is a supplementary parking aid system to display the rearview when the gear selector lever is moved into R
position.
R position
Rearview camera
Power supply
Operates only when the gear selector lever is
The rearview camera displays the rearview
in R position
Front monitor
Rear monitor
The rear monitor displays the rearview only

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

STAVIC - 2004.09
2H
13
1. OPERATIONAL PRINCIPLE OF REARVIEW CAMERA

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

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

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2H
2. REARVIEW CAMERA OPERATION

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

The rearview camera is securely installed on the rear spoiler with high torque and strong adhesive. Do not apply excessive force to remove it. Otherwise, it could be damaged.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
2I
EXTERIOR LAMPS
1. LOCATIONS OF EXTERIOR LAMPS
Front Lamps
Side turn signal lamp:

one at each side (12V - 5W)
Headlamp
Headlamp
: one at each side (12V - 5W)

Fog lamp (RH)
Fog lamp (LH)
Tail lamp:
Low beam:
High beam:
Turn signal lamp:

Tail lamp
Connector
3
4
Headlamp
(High beam)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Headlamp
(Low beam)
Tail lamp/Turn signal lamp

connector
Turn signal lamp
LAMP
STAVIC - 2004.09
2I
Rear Lamps
High mounted stop lamp
: center 1 (12V 5W)
Tail lamp assembly
License plate lamp

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

Tail lamp: one at each side (12V - 8W)
Stop lamp
Tail lamp assembly

connector
Rear turn signal lamp/Rear fog lamp
Tail lamp
LAMP
STAVIC - 2004.09
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EFFECTIVE DATE
AFFECTED VIN
2I
2. AIMING AND ADJUSTMENT OF FRONT LAMP

Headlamp Aiming
An approved beam setting device should be used for a
correct headlamp aiming.
Headlamp aiming requirements:
Make sure to follow the operating instructions provided by

the manufacturer.
- specified tire pressure
If not available to use the beam setting device, adjust the

headlamp aiming with a screen.
- spare tire and OVM tools loaded (unlade all other loads)
- parking on a flat surface

- one passenger (driver, 65 kg),
Adjustment of low beam

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

No.3 adjustment hole: Up and Down
No.4 adjustment hole: Left and Right
CHANGED BY
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AFFECTED VIN
No.1 adjustment:
No.2 adjustment:
No.3 adjustment:
No.4 adjustment:
Direction A - Up
Direction C - Left
Direction E - Up
Direction G - Left
Direction B - Down
Direction D - Right
Direction F - Down
Direction H - Right
LAMP
STAVIC - 2004.09
2I
Cautions During the Aiming

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

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

1. Align the vehicle and beam setting device according to the operating instructions provided by the manufacturer.
2. Adjust the headlamp aiming by rotating the direction control levers (Up, Down, Left, Right) in turn with a screwdriver.
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2I
When Using a Screen

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

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

aiming by rotating control levers (Up, Down, Left, Right)
in turn with a screwdriver.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
Fog Lamp Aiming Adjustment
1. Down
The lamp aiming moves down

when the knob is turned to direction 1 (clockwise).
2. Up
The lamp aiming moves up when
the knob is turned to direction 2
(counterclockwise).
Knob
To adjust the fog lamp downwards
Fog lamp
1 - Clockwise
Down
Knob
To adjust the fog lamp upwards
2 - Counterclockwise
Fog lamp
Up
Knob
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2I
3. REMOVAL AND INSTALLATION OF EXTERIOR LAMPS

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

Lamp cover
Lamp cover
1. Headlamp assembly
Bulb
4. High mounted stop lamp
7. Rear tail lamp assembly
CHANGED BY
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AFFECTED VIN
5. License plate lamp
6. Tail lamp (back-up lamp)
LAMP
STAVIC - 2004.09
2I
1) Headlamp Assembly
The headlamp assembly consists of position lamp, headlamp low beam, headlamp high beam, and front turn signal lamp.
1. Remove two bolts on the lamp housing.
2. Remove one bolt in engine compartment, disconnect two connectors, and remove the lamp assembly.
3. Carefully remove the headlamp.

Cover rubber ring
[Notice]
If the cover rubber ring is worn, replace it with new one.
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
2I
Replacement of Headlamp Bulb

1. Remove the headlamp dust cover.
High beam cover
Low beam cover
2. Disconnect the headlamp bulb connector.
3. Push up the bulb clamp to remove it.

Push
Remove
CHANGED BY
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AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
11
4. Remove the bulb and install new bulb with same

specifications.
Replacement of Tail Lamp/Turn

Signal Lamp
1. Disconnect the tail lamp/turn signal lamp connector from
the headlamp assembly.
2. Remove the tail lamp/turn signal lamp bulbs from the headlamp assembly and install new bulb with same
specifications.
Tail lamp bulb assembly
Turn signal lamp bulb assembly
Headlamp (low beam) bulb assembly
Headlamp (high beam) bulb assembly
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
2I
2) Fog Lamp Assembly

Removal and Installation of Fog Lamp Assembly
1. Disconnect the fog lamp connector.

2. Remove the mounting screws (when removing the
assembly).
3. Remove the fog lamp bulb (when only removing

the bulb).
4. Remove the fog lamp assembly.

Lamp cover
Lamp
Bulb connector
Mounting screws
Bulb
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
13
3) Side Turn Signal Lamp Assembly

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

If the cover rubber ring is defective,
replace it with new one.
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
2I
4) High Mounted Stop Lamp Assembly

Removal and Installation of High Mounted Stop Lamp
1. Remove the high mounted stop lamp cover from the tailgate spoiler.
[Notice]
Be careful not to damage the installation surface when removing the tailgate spoiler.
Adhesive area
High mounted spoiler
Adhesive area
Adhesive area
Lamp
Mounting screw
Mounting screw
Lamp cover
2. Unscrew the screws from the high mounted stop lamp, disconnect the lamp connector, and remove the lamp assembly.
Tailgate spoilera
Rearview camera
High mounted stop lamp bulb
Rearview camera cover
High mounted stop lamp
High mounted stop lamp cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
15
5) License Plate Lamp Assembly

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

1. Remove the tailgate inner trim.
2. Disconnect the back-up lamp connector (1) and remove

the nuts (2) from the tail lamp (back-up lamp) assembly.
Fog lamp /
Back-up lamp
3. Remove the tail lamp (back-up lamp) assembly and pull out the bulb from the removed tail lamp assembly.
Bulb connector
Bulb connector
Tail lamp
(back-up lamp)
/ Fog lamp
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
2I
7) Tail Lamp Assembly

1. Open the tailgate and remove two screws from the tail lamp assembly.
Tail lamp assembly (RH)
Tail lamp assembly (LH)
2. Disconnect the connector and remove the tail lamp assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
17
3. Remove the bulb connector by rotating it counterclockwise from the removed tailgate lamp assembly. Pull out the
bulb from the bulb connector and install the new bulb with same specifications.
Tail (stop) lamp
Rear fog lamp

/ Rear turn signal lamp
Bulb connector
Tail (position) lamp
LAMP
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
18
2I
INTERIOR LAMPS
1. LOCATIONS OF INTERIOR LAMPS
1. Front room lamp
: one at both sides (12V 5W)
(coupled operation with door)
Side (third row set) room lamp
Rear room lamp switch

(coupled operation with door)
Side (second row set) room lamp
The front room lamps (1, 2) are turned on when pushing the lamp
body regardless of the positions of front room lamp coupled switch.
Press the lamp body again to turn off.
Front room lamps (drivers and passengers) are turned on when
opening one of front doors with this switch (A) pressed in.
2. Rear room lamp (in second and third row seats)

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

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

a door.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
19
4. Luggage room lamp

: one at center (12V 5W)
Rear (third row set) room lamp
Rear (second row set) room lamp
Front room lamp

Luggage room lamp is turned on and off when the
switch (1) is pressed in and out.
Glove box lamp
Luggage lamp is turned on and off when opening

and closing one of rear doors with the front room
lamp switch pressed in.
Center console lamp
5. Glove box lamp

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

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

the ignition switch is in ON position.
LAMP
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
20
2I
2. DOOR COUPLED ROOM LAMP SWITCH OPERATION

Front/Rear Door Coupled Operation
Door coupled room

lamp switch
1. Front door coupled

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

lamp switch
1. Rear room lamps (A) and luggage room lamp (B) are turned on when
opening a rear door with this switch (2) pressed in. The lamps are
dimmed out after closing the door.
2. Rear and luggage room lamps are turned on only when the side room
lamp coupled switch is pressed in.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
21
3. REMOVAL AND INSTALLATION OF INTERIOR LAMPS

Locations of Interior Lamps
1. Door courtesy lamp
2. Luggage room lamp
3. Glove box lamp assembly
4. Interior room lamp assembly 5. Front room lamp assembly 6. Center console lamp assembly
LAMP
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
22
2I
1) Door Courtesy Lamp Assembly

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

1. Open the glove box cover and push down the front portion of the lamp. Disconnect the connect and remove the
lamp assembly.
2. Disconnect the lamp connector and remove the lamp. However, it is not necessary to disconnect the connector
when removing only the bulb.
3. Install in the reverse order of removal. Replace the bulb with new one with same specifications.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
23
3. Luggage Room Lamp Assembly

1. Open the tailgate and remove the luggage room lamp cover with a flat blade screwdriver. At this time, be careful not
to damage the surroundings.
2. Remove the bulb from the luggage room lamp with new one with same specifications.
Bulb
LAMP
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
24
2I
4) Side Room Lamp Assembly

1. Unscrew the screws and remove the side room lamp
assembly.
[Notice]
1. Be careful not to damage the lamp cover when removing it.
2. Replace the bulb with new one with same specifications.
2. Disconnect the lamp connector (1), unscrew the screws from the removed room lamp assembly, and remove the
lamp.
* when removing the bulb

Remove the lamp cover (1) and pull out the bulb (2). Be careful not to damage the lamp cover when removing it.
CHANGED BY
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AFFECTED VIN
LAMP
STAVIC - 2004.09
2I
25
5. Front Room Lamp Assembly

Removal and Installation of Front

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

connector (2).
4. Remove the bulb from the removed front room lamp. Install in the reverse order of removal.
LAMP
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
2I
* when replacing the bulb
Remove the lamp cover (1) and pull out the bulb (2).
[Notice]
1. Be careful not to damage the lamp cover when removing it.
2. Replace the bulb with new one with same specifications.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
LAMP
STAVIC - 2004.09
3A
AIR CONDITIONING SYSTEM

1. SYSTEM LAYOUT AND COMPONENTS
Type
Air conditioner controller
Sun load sensor - instrument

panel upper left
FATC
Manual air
conditioner
It changes sun load coming through front
windshield into current to input to FATC
controller.
AQS/Air source selection

switch
Compressor engine right
A function that turns on/off the air

source selection and air quality system.
Driven by engine and transmits refrigerant from condenser to inside of vehicle.
Front air conditioner module assembly inside instrument panel

Air mix door
actuator
Air source door

actuator
PTC (If equipped)

Air conditioner filter
Duct temperature
sensor
Blower motor
Blower high
speed relay
Mode door
actuator
Air conditioner
wiring
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AFFECTED VIN
Thermo AMP
Power transistor

STAVIC - 2004.09
3A
Receiver drier
Condenser right
Absorbs moisture in the refrigerant and

reserves refrigerant to supply smoothly.
Condenser
Installed in front of vehicle and condenses

vapor refrigerant into low temperature and
high pressure liquid refrigerant.
Engine ECU passengers

footstep
Detects A/C AUTO switch position, coolant temperature, engine condition and driving condition to control the air conditioner.
Sub-condenser
right wheel front
Condenses high temperature and high

pressure vapor refrigerant into low-temperature-high-pressure liquid refrigerant.

on engine
A sensor that detects coolant temperature

and transmits to engine ECU.
Rear air conditioner module assembly bottom of rear left

Front
Blower motor
Air conditioner high

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

STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
3A
2. VENTILATION SYSTEM
1) Locations of Vents
Front Ventilation
Rear ventilation
Air conditioned air flows
Heated air flows

Heater vent
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STAVIC - 2004.09
3A
2) Ventilation Modes
* Vent mode
* Bi-level mode
* Floor mode
* Defrost and floor mode
* Defrost mode
* Rear air conditioning mode

STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
3A
3. AIR CONDITIONER MODULE WIRING AND LAYOUT

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

Manual: blower resistance
Thermo amp
(FATC, manual)
Components
Air conditioner filter
Evaporator
Air source selection

door actuator
Blower
motor
Blower high
speed relay
Heater core
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
3A
2) Rear Air Conditioner Module

Wiring layout
Rear blower motor

Rear blower relay (Hi)
Rear power transistor
Air mix motor
C305 A/C
wiring
(RR)
Components
Roof air conditioner duct
Blower motor
Air mixer door actuator
Rear floor heater duct
Evaporator
Mixer door
Heater core

STAVIC - 2004.09
Heater & air conditioner

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

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

display and malfunction of each sensor in air conditioner
control system is also displayed.
- When controlling the fan speed by rotating
this switch in AUTO mode, the mode is
Temperature control switch and

AUTO button
changed from AUTO to manual and the fan

speed can be changed in 6 stages.
- When pressing the air conditioner AUTO mode

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

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

Rear air conditioner switch: ON (can control
the rear fan speed in rear seats)
Front/rear independent cooling/heating

1. Front: Air conditioner operation 2. Front: No air conditioner operation 3. Rear: Heater operation and control
Rear: Heater operation
Front air conditioner: ON
Front air conditioner: OFF
Rear air conditioner switch: R position
Rear fan control switch: 1, 2, or 3 position
Rear heater switch: ON
Fan control switch in rear seats: can control the rear fan speed
CHANGED BY
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STAVIC - 2004.09
3A
Air conditioner OFF switch
A/C switch: When pressing this switch, the air conditioner operates in manual mode and A/C ON indicator comes
on.
AQS system
- Air Quality System (AQS) changes the air source selection to
recirculation mode when polluted air is detected through AQS
sensor. The air source selection returns back to fresh air intake
mode after a specified period or the polluted air is disappeared
(refer to AQS and ambient temperature sensor).
Defroster switch
When pressing this switch, the airflow direction will be changed

to windshield and door glasses, the air conditioner operates automatically and outside air comes in. At this moment, the defroster
indicator, air conditioner indicator and fresh air mode indicator
come on. When pressing the switch again, the air conditioner returns back to normal operations.
When pressing the AUTO switch, the defroster mode appears
on the VFD until the coolant temperature reaches at a certain
level.
MODE switch
- By depressing this switch, the airflow mode is changed.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
3A
Manual Air Conditioner Controller

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

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

(can control the rear fan speed
in rear seats)
Front/rear independent cooling/heating

1. Front: Air conditioner operation
2. Front: No air conditioner operation
3. Rear: Heater operation and control
Front air conditioner: ON
Front air conditioner: OFF
Rear air conditioner switch: R position
Fan control switch in rear seats: can

control the rear fan speed
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AFFECTED VIN

STAVIC - 2004.09
3A
11
Defroster switch
A/C switch
Operates air conditioner by turning on blower motor and compressor.
When pressing this switch, the airflow direction will be

changed to windshield and door glasses, the air conditioner operates automatically and outside air comes in. At
this moment, the air source selection indicator goes off.
Mode switch
Vent mode
The air flows towards face and
the indicator comes on.
Defroster and floor mode

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

When pressing this switch, the air recirculates in the vehicle inside and indicator comes on. When pressing it again, the indicator
goes off and the fresh air comes in.
Rear heater switch

When pressing this switch, the rear heater operates and the indicator comes on.
(However, under defroster mode or defroster/floor mode, it stays

in the fresh air mode.)

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5. SELF DIAGNOSIS (ONLY FOR FATC AIR CONDITIONER)

Self Diagnosis Code
The FATC controller has self diagnosis function that can diagnose the system by itself. Before checking each component,
be sure to check the default code by using self diagnosis function.
Code
Malfunction
Remark
Code
Malfunction
Remark
Normal
Defective interior temperature sensor
25
Defective AQS
Defective ambient temperature sensor
25
10
Defective humidity sensor
Defective duct sensor
11
Defective air mix door motor
12
Defective intake door
Defective sun sensor
13
Defective power transistor
14
Defective blower high relay
15
Self Diagnosis
1. Set the temperature to 26C with the temperature control switch (AUTO), and press the OFF switch 3 times within
3 seconds after temperature setting while the AUTO switch is pressed.
AUTO switch
Self diagnosis display
Press OFF switch 3 times.
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2. At this moment, the air conditioner controller performs the self diagnosis procedures.
3. The Micro computer integrated in controller displays the defect codes in turns on the VFD after performing self
diagnosis. Below figure shows the defect code caused by disconnecting the interior temperature sensor/humidity
temperature sensor connector.
Defect code ON
Defect code ON
4. After displaying defect code, operates again in AUTO mode.

[Note]
For sun sensor, the diagnosis for short circuit is only available. When the switch circuit is opened, the system recognize it
as a night.

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Phenomenon when Air Conditioner System is Defective

(Initial Automatic Diagnosis)
- If any sensor in the air conditioner system is defective, the temperature display blinks about 3 times during initial
operation of air conditioner controller.
Current setting
temperature blinks
- If the setting temperature starts to blink, the self diagnosis starts to check the conditions of defective sensor.
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6. SYSTEM DIAGRAM
User
Control
Setting
temperature
Power
transistor
Blower high
speed relay
Ambient
temperature
Fan speed control

(Blower motor
control)
Duct
temperature
Environments
Interior
temperature
Sun loads
Air
conditioner
controller
AQS sensor
Vehicle
information
Air mix motor
Temperature control
Mode motor
Air flow control
Air source
selection motor
Air source selection

control
Vehicle
speed
Wiper
operation
Engine ECM
Compressor control
Air Conditioner Compressor Control by Engine ECU

In case of current vehicle models, the system turns ON/OFF the compressor switch according to refrigerant pressure,
ambient temperature and condenser temperature to protect air conditioner circuits. However, for the vehicle equipped
with DI engine, the engine ECU turns off air conditioner compressor as below in addition to above conditions.
1. Coolant temperature: below -20C
2. Coolant temperature: over 115C
3. For approx. 4 seconds after starting the engine
4. When engine speed is below 650 rpm
5. When engine speed is over 4,500 rpm
6. During abrupt acceleration for the vehicle equipped with manual transmission

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7. CIRCUIT DIAGRAMS IN AIR CONDITIONER SYSTEM

FATC (Full Auto Temperature Control)
1) Condenser fan, air mix motor, sun load, coolant temperature sensor
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2) Front blower, motor (mode/air source selection), inside air/humidity, outside air/AQS sensor

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3) Rear air conditioner (blower, mode actuator)
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Manual Air Conditioner

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

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2) Blower motor (front, rear)
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Inspection
If the active incar sensor defect code (DTC 1) and the humidity sensor defect code (DTC 10) are set, check as below:
Air conditioner controller
Air conditioner controller connector

(based on wiring)
[Active incar sensor]

1. Remove the integrated AIH sensor and measure the
resistance between terminal No. 5 and 6 on the
sensor connector.
(standard: approx. 25C, 2.2 k)
2. If the measured value is out of the specified range,
replace the AIH sensor. If the measured values are
within the specified range, check as below.
3. Turn the ignition switch to ON position and measure
the voltage to active incar sensor from the FATC
controller connector.
(standard: approx. 2 V at 25C)
4. If the voltage value cannot be measured, check the
circuit for open. If the measured value is within the
specified range, replace the FATC controller.

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AIH sensor (based on sensor)
[Humidity sensor]
1. Apply 5 V to terminal No. 1 and 3 on the humidity
sensor connector.
2. Connect the positive (+) probe of a tester on No. 2
terminal and the negative (-) probe on No. 3 terminal,
and measure the output voltage while the voltage is
applied.
(output voltage: approx. 0.8 ~ 3.4 V)
3. Check whether the output voltage is changed when
blowing into the inlet of the sensor. If there is a voltage
change, the sensor is in normal condition. However,
if the voltage is not changed, replace the humidity
sensor.
4. In addition, if the output voltage is extremely high or
low even in the specified range, replace the humidity
sensor.
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9. AIR QUALITY SYSTEM (AQS)

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

The AQS switch is integrated with the air source selection switch.
AUTO Mode
The air source is not changed when pressing the AQS and air source
selection switch in AUTO mode. However, the indicator on the
switch turned ON/OFF. In other words, the air source cannot be
changed to recirculation mode in AUTO mode by just pressing the
switch.
To change the air source to recirculation mode in AUTO mode, get
into Manual mode first, then press the air source selection switch.
Manual Mode
To change the AQS mode to Manual mode from AUTO mode, use
the MODE switch or the fan speed control dial. In Manual mode, the
AUTO symbol on the display is disappeared. When pressing the
AQS and air source selection switch, the mode is changed in order
of AQS LED ON, AQS LED OFF (fresh air), and air source LED ON
(recirculation).
The figure shows that the mode has been changed to the recirculation mode from fresh air mode under AQS mode (AQS LED ON)
after detecting the polluted outside air.
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2) AQS Operation
The AQS operates under air conditioner AUTO mode or when the AQS switch is pressed under manual mode. It requires
preheating time (for seconds) for operation and the module and sensor are integrated.
(However, it operates only when the DEF (defroster) switch on the air conditioner switch panel is not pressed in.)
1. Self diagnosis and preheating process during initial operation of A/C controller (AUTO mode)
1. When the air conditioner controller is operated in AUTO
mode during its initial operation, the air source is changed
to the recirculation mode and AQS LED comes on.
(This is the self diagnosis and preheating process for
AQS.)
2. After completing the above process, the AQS LED is
turned off and the air source is automatically changed to
the fresh air mode.
[Note]
If the AQS switch is pressed in, the AQS function works
regardless of air conditioner controller operation.
2. AQS operation (AQS switch is pressed in): detecting the polluted outside air
1. When pressing the AQS switch, the LED on the AQS
switch is turned on and the AQS function is activated.
2. When the polluted outside air is detected, the AQS
operates and converts the air source to recirculation mode
automatically. At this moment, the recirculation mode
indicator comes on in the display.
3. When driving out of polluted area

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

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3) AQS Operation Circuit
5. IGN2
3. AQS signal (Output)

1. Ambient temperature switch
2. Sensor ground
4. Ground

2. Sensor ground
3. AQS signal (Output)
4. Ground
5. IGN 2
[AQS sensor]
1. Measure the voltage value of AQS.
(between connector terminal No. 3 and 4.)
2. If the measured voltage is out of 0.1 to 4.8 V, replace
the AQS.
3. If the measured voltage is out of the specified range,
replace the AQS. If it is within the specified range,
check as below.
4. Turn the ignition key to ON position.
5. Measure the voltage between terminal B9 and B15
on the air conditioner controller.
[Ambient temperature sensor]

1. Remove the sensor and measure the resistance
between terminal No. 5 and 6 on the sensor
connector.
In addition, if the resistance is extremely high or low,
replace the sensor.
2. If the measured value is out of the specified range,
replace the ambient temperature sensor. If the
measured value is within the specified range, check
as below.
3. Turn the ignition switch to ON position and measure
the voltage to ambient temperature sensor from the
FATC controller connector.
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4) Removal and Installation

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

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10. AIR CONDITIONER MODULE SENSORS AND ACTUATORS

1) Duct Temperature Sensor
The duct temperature sensor is installed on the top of heater unit. It detects the inside temperature of duct and transmits
the voltage value that is changed according to resistance value (NTC) to FATC controller.
Inspection
If the duct temperature sensor defect code (DTC 3) is set, check as below.
1. Remove the duct temperature sensor and measure the resistance between terminals on the sensor connector.
In addition, if the resistance is extremely high or, replace the sensor.
2. If the measured value is out of the specified range, replace the duct temperature sensor. If the measured value is
within the specified range, check as below.
3. Turn the ignition switch to ON position and measure the voltage to duct temperature sensor from the FATC controller
connector.
4. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.
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2) Power Transistor
The power transistor controls the fan speed. It controls the blower motor operating speed without stages by changing
the current value to the base of power transistor when receiving the fan control signal from FATC.
Front air conditioner power transistor
Rear air conditioner power transistor
Inspection
If the power transistor defect code (DTC 6) is appeared, check as below.
2. Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6.
3. The specified voltage value in each stage:
Stage
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
Stage 6
Blower (V)
4.5
6.0
7.5
9.0
11
Max. HI
4. If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the
power transistor.

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3) Mode Door Actuator

The mode door actuator is an actuator that closes, opens and adjusts the mode door for VENT, FLOOR and DEF mode
to change the air flow directions according to FATC controller. Under the FATC controller AUTO mode, it stays on DEF
mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when
the MODE switch is pressed.
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Inspection
Terminal arrangement
Circuit diagram
If the intake door mode on FATC is different from the actual intake door mode, check as below.
2. Measure the voltage between each terminal (P1 through P5)and positive (+) terminal in respective mode.
(If the voltage is changed from 0 V to 12 V after selecting the mode, it is normal.)
3. If the voltage value is out of the specified value, check the related circuits for open.
4. If the circuits are in normal condition, replace the FATC.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the door mode actuator. And, connect
the negative cable to each terminal (P1 through P5) to check its operation.
(If it operates as shown in above figure, it is normal.)

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4) Air Door Actuator

The air door actuator sets the intake door mode according to the control signals from FATC.
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Inspection
Circuit diagram
If the intake door mode on FATC is different from the actual intake door mode, check as below.
2. Measure the voltage between terminal P1 and P2 (approx. 12 V) and terminal a and b (approx. 5V).
4. If the circuits are in normal condition, replace the air door actuator assembly.
5. If the voltage is within the specified value, replace the mode door actuator assembly.
6. Connect the positive (+) and negative (-) cables of temporary power supply to the air door actuator. And, connect
the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output.
Air source
Mode
Bc resistance
Fresh air
P1 (-), P2 (+)
below 300
Recirculation
P1 (+), P2 (-)
over 2.4 k

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5) Air Mix Door Actuator

The air mix door actuator controls the discharging air temperature properly by closing/opening the damper according to
the control signals from FATC.
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Inspection
Circuit diagram
If the air mix door defect error is indicated, check as below.

2. Measure the voltage between terminal P1 and P2 (approx. 12 V) and terminal a and b (approx. 5V).
4. If the circuits are in normal condition, replace the air mix door actuator assembly.
5. Connect the positive (+) and negative (-) cables of temporary power supply to the air mix door actuator. And,
connect the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output.
AMD
Mode
Bc resistance
Cool
P1 (-), P2 (+)
below 300
Hot
P1 (+), P2 (-)
over 2.4 k

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

1. Remove the thermo AMP and measure the voltage between terminal No. 1 and 2 on the connector.
2. Check whether the output voltages (ON: approx. 12 V, off: 0 V).
3. If the voltage value is out of the specified value, replace the thermo AMP. If the circuit is in normal condition, check
as below.
4. Turn the ignition switch to ON position and turn on the air conditioner by pressing the A/C button. And measure the
voltage between terminal A12 and A11 on the FATC controller connector. (standard: approx. 12 V)
5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified
range, replace the FATC controller.
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11. AIR CONDITIONER AND HEATER PIPE LAYOUT

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Removal and Installation of Sensors and Actuators

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

All removal and installation operations for sensors and actuators
have similar procedures.
1. Disconnect the corresponding connector (1).
2. Remove the mounting bolts for each mode actuator.
However, the thermo AMP and blower high speed relay can be
removed only after removing the air conditioner module.
Duct temperature sensor
Mode door actuator
Mode door actuator:

Disconnect the door link (A) and then disconnect the
connector and remove the bolts.
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Thermo AMP
The thermo AMP is installed on the
heater core inside of air conditioner
module.
Air door actuator
Make sure that the parts (2) of air door actuator is securely
seated when installing it.
Power transistor

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12. REMOVAL AND INSTALLATION OF THE RELATED COMPONENTS

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

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

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

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3. Rear air duct assembly

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

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

assembly.

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, unscrew the mounting screws and remove the blower unit
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3. Disconnect the ground cable
, unscrew the mounting screws and remove the heater unit assembly.
Heater pipe mounting nut
Heater module mounting nuts (side)
Ground cable (A) and mounting nut

(bottom)
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Rear Air Conditioner Module

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

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and heater duct
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2. Remove the rear air conditioner module assembly with the sequence as below:
1) Remove the heater hose/pipe
2) Remove the air conditioner high and low pressure pipes

3) Disconnect the connector
4) Remove the rear air conditioner module mounting screws
5) Unscrew the lower mounting screw and remove the rear air conditioner module assembly.
Heater/air conditioner pipe
Lower mounting screw
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3. Remove the rear air conditioner module assembly.
4. Install in the reverse order of removal. Make sure that no air leaks on the connections of heater and cooler duct.
Top of A/C duct
Top of heater duct
Bottom of A/C duct

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4) Receiver Drier and Condenser

Preceding works: 1. Collection of air conditioner refrigerant (dispose the wasted refrigerant to designated place)
2. Removal of front bumper assembly
1. Remove the turbo charger cooler assembly.
- Tightening torque for hose: 6 ~ 7 Nm
2. Disconnect the cooling fan (condenser) connector

cooling fan.
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, unscrew the mounting bolts
and remove the condenser

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

condenser.

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5. Unscrew the lower mounting bolt and remove the receiver drier. The O-rings on the pipes should be replaced with
new ones. (Tightening torque: 20 ~ 30 Nm)
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5) Compressor Assembly
Preceding works: 1. Disconnection of negative battery cable and removal of fan belt
1. Remove the two air conditioner pipe flange bolts
at compressor side and disconnect the connector
(At this moment, the sealing washer on the pipe flange bolt should be removed. And, it should be replaced with new
one during installation)
B. Connector
A. High/Low pressure pipe flange bolt

(10 ~ 15 Nm)
2. Unscrew the compressor mounting bolt
C. Compressor mounting bolt (20 ~ 30 Nm)
remove the compressor from the engine.

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

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3B
FFH (FUEL FIRED HEATER) SYSTEM

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

FFH assembly
Heater / A/con module (front)
PTC (If applied)
Front duct
Air conditioner control panel
Rear floor duct

FFH fuel pump
Roof duct (A/con)
Rear duct (heater)

Fuel tank
Heater / A/con module (rear)
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3B
3. SYSTEM LAYOUT
FFH Overview
1. FFH assembly
2. Water pump & bracket

9. Suction hose
3. FFH NO.1 bracket assembly
10. Fuel pipe NO.1
4. FFH NO.2 bracket assembly
11. Fuel pipe NO.2
5. Silencer & pipe assembly
12. Pump outlet hose assembly
6. Fuel pump assembly
13. FFH inlet hose assembly
7. Fuel pump bracket assembly
A. FFH assembly
FFH & PTC
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3B
FFH Heater Disassembly
CHANGED BY
FFH & PTC
EFFECTIVE DATE
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3B
1. Jacket
18. Surface sensor with cable
2. Jacket cover
19. Controller connector -14-pin connector (waterproof)
3. Combustion air fan
20. Pressure spring for surface sensor
4. Combustion chamber
21. Pressure spring for control and overheating sensor
5. Combustion chamber with flame tube
22. O-ring
6. Heat exchanger
23. Coolant hose (inlet)
7. Controller
24. Coolant hose (outlet)
8. Seal (between combustion chamber and
25. Tooth ring (2x)
combustion air fan)

9. O-ring
26. Cable harness cover

27. Rubber seal
10. Glow plug with cable
28. O-ring
11. Seal (between combustion chamber and heat
29. Screw (M4 x 55 TORX/2x)
exchanger)
12. Upper bush for fuel pipe
13. Lower bush for fuel pipe
14. Flame sensor
15. Bush for flame sensor (graphite)
34. Controller cable harness
16. Control and overheating sensor with cable
35. Insulation washer
17. O-ring
FFH & PTC
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4. FFH SPECIFICATION
Heater
D 5 S-H
Heating medium
Coolant
Control of the heat flow

Heat flow
Fuel consumption per hour
Mean electric power consumption
in operation
Large (full load)
Small (small load)
5000 W
2300 W
0.63
0.28
35 W
11 W
at start
100 W
after-running
12 W
12 V
Rated voltage
Operating range
Lower voltage limit: An undervoltage protection
device in the controller switches the heaters off at
approx. 10 volt.
Upper voltage limit: An overvoltage protection device
in the controller switches the heaters off at approx.
15 volt.
15 V
up to 2.5 bar overpressure
Tolerable operating pressure

Minimum water flow through the heater
300 L/H
In the main fuel tank
Fuel
Tolerable ambient temperature
10 V
operation
storage
Weight
(with controller, water pump and fuel pump)
-40C ~ 80C
-40C ~ 125C (2h for 125C)
approx. 2.7 kg
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
5. FFH OPERATING PROCESS

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

Initial Operating Conditions of FFH:
Ambient temperature: below 5C
Coolant temperature: below 75C
Repeat Operating Conditions of FFH:
Coolant temperature: below 75C
When the difference between the ambient temperature at initial operation and current ambient temperature is
over 3C (to reduce the hysteresis with the temperature difference when operating FFH), FFH is operated
again. For example, if the initial operating temperature was 4C, the ambient temperature at repeat operation
should be below 1C and the coolant temperature should be below 75C.
FFH operations according to the changes of coolant temperature
Above graph shows the FFH control process while the FFH is operating.
The control element is coolant as shown in the graph.
The FFH is operated in HI mode (high output: approx. 5000 W) until the coolant temperature reaches at 80C and starts
to be operated in LO mode (low output: approx. 2300 W) from 81C.
When the coolant temperature reaches at approx. 85C, FFH stops its operation until the operating conditions will be
met again.
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
10
3B
Coolant Circulating Route
Rear
Water pump
Engine
Fan
Heater module
Front
Heater
Blower fan
Heater module
Heating system
Connecting the Coolant Circuit

The heater is connected to the coolant circuit in the coolant feed pipe from the vehicle engine to the heat exchanger.
[Notice]
Parts conveying coolant must be routed and fastened in such a way that they pose no temperature risk to person or
material sensitive to temperature from radiation and direct contact.
Before working on the coolant circuit, disconnect the negative battery cable and wait until all components have cooled
down completely.
When installing the heater and the water pump, note the direction of flow of the coolant circuit.
Fill the heater and water hoses with coolant before connecting to the coolant circuit.
When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts.
Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures.
Secure all hose connections with hose clips.
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
11
Circuit Diagram
The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation pump
and the ambient temperature sensor (switch) that provides important signals for the initial and repeat operations.
For diagnosis, remove the FFH system connector and install the scan tool. Currently, the K-Line that is connected to
the diagnostic connector is not available.
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
12
3B
Control and Safety Mode

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

Rated voltage
Operating voltage
Power consumption
Pumping capacity (0.1 bar)
Weight
12 V
9 V ~ 15 V
16 W
800 l/h
-40C ~ 135C
0.28 kg
Characteristic Curve of Water Pump (12 V)
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
13
Function Diagram
Control stage large
Control stage
small
Sectional Drawing According to the Temperatures
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
14
3B
6. FFH ASSEMBLY
[Notice]
There is no need to disassemble the FFH unit for repair. This section is to show the internal components of the FFH unit.
Jacket cover
- The O-rings are installed between jacket cover and two
coolant hoses.
- The coolant hoses should be connected to right side.
1. Jacket
2. Jacket cover
3. Cable harness cover
Control and overheating sensor

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

Check the control and overheating sensor with a digital
multimeter. If the resistance according to the changes of flame
sensor temperature is out of specified values, the flame sensor is defective.
Resistance (Ohm)
2. Mounting spring
Temperature (C)
Specified value
Temperature [C]
Resistance []
10
20
32.54 19.87 12.48
30
40
50
60
70
80
90
100
110
120
8.06
5.33
3.60
2.48
1.75
1.25
0.91
0.67
0.50
0.38
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
15
Surface sensor
The surface sensor and cable harness make up one
component.
1. Surface sensor
2. Mounting spring
Resistance (Ohm)
Check surface sensor

Check the surface sensor with a digital multimeter.
If the resistance of flame sensor is out of specified
values, the flame sensor is defective.
Temperature (C)
Specified value
Temperature [C]
Resistance []
10
20
30.00 19.53 13.03
30
40
50
60
70
80
90
100
110
120
8.90
6.20
4.41
3.19
2.34
1.75
1.32
1.02
0.79
0.62
Controller
The surface heater and cable harness make up one
component.
3. Combustion chamber housing
4. Surface sensor assembly
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
16
3B
Glow plug
1. Glow plug
2. Combustion chamber with flame pipe
Combustion chamber housing

1. Jacket
3. Combustion chamber housing
4. Insulation washer
5. Seal - combustion chamber / combustion air fan
6. Seal - combustion chamber / heat exchanger
Flame sensor
1. Flame sensor
2. Graphite bush
3. Bush
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
17
Resistance (Ohm)
Check flame sensor

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

2. O-ring
3. Rubber seal
4. Combustion air fan
5. Screw
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
350
400
18
3B
Combustion chamber
2. Heat exchanger
3. Jacket
4. O-ring
Heat exchanger
1. Jacket
2. Heat exchanger
3. Combustion chamber with flame tube
5. O-ring (for heat exchanger)
Heat exchanger
1. Heat exchanger
2. Jacket
3. Stopper
4. Groove (bottom of heat exchanger)
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
19

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

1. Disconnect Fuel Pump Connector as the vehicle lifted.
2. Disconnect both left (2) and right (3) fuel supply hose
in above picture.
Fuel Tank
3. Unscrew fuel pump mounting bolt (10M-1EA) and

disassemble fuel pump.
Tightening torque
10 1.0 Nm
FFH
[Notice]
Cap the fuel supply hose to prevent oil leakage
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
20
3B
Ambient Temperature Switch

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

holder (2).
2. Disconnect connector (4) as push the connector pin (3).
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
21
FFH Assembly
Preceding Work: Disconnect the battery terminal (-)
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
22
3B
1. Disconnect FFH coolant circulation pump connector.

2. Disconnect FFH connector (2).
3. Disassemble the fuel pump hose and pipe.

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

the inlet (3) & outlet (2) hose in coolant circulation pump.
Tightening torque
10 1.0 Nm
5. Disconnect the coolant outlet hose (1).
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
23
6. Disconnect the FFH assembly. (Install in the reverse order of removal)

( Fuel feeding process should be done)
: Silence braket bolt

: Left/ Right
(10mm - 2EA)
1. FFH Mounting
bolt (10mm - 6EA)
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
24
3B
Fuel Feeding Process

Fuel Feeding job should be followed after changing FFH assy or after fuel line job.
[Notice]
Picture B
Without feeding job, FFH system could make white

smoke with abnormal noise.
1. Disconnect the ambient temperature switch as

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

FFH assembly and keep the engine running for
1 minute.
4. Connect the ambient temperature connector.
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
25
8. TROUBLE DIAGNOSIS
1. FFH Heater Trouble Diagnosis Precedure
When Faults Occur, First Check
Faulty wiring?
(short circuits, interruptions)
Visual check for
-
corroded contacts
defect fuses
damaged electrical leads, links and connections
damaged exhaust and combustion air guidance
Check battery voltage

Battery voltage < 10 volt: the undervoltage protection has triggered
Check fuel supply
Check Voltage Supply Ubatt (terminal 30)

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

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

If FFH performs 10 start attempts in vain, error code 050 appears and the controller is locked.
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
26
3B
SCAN100 Diagnosis
1. Vehicle
2. Choose No.11 item FFH
3. Choose trouble code checking.
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
27
DTC (Diagnosis Trouble Code)

Trouble
Code
Trouble Description
Remedies
No faults
Measure battery voltage (must be < 15.9V)
10
Shutdown for overvoltage
Check alternator
11
Shutdown for undervoltage
Check alternator over voltage

Measure battery voltage (must be > 10.2V under load)
Check alternator
Check lead
12
Overheating (software threshold)
Temperature at overheating sensor >125C

Check cooling system:
Check the temperature sensor and overheating sensor, replace
if necessary
14
Overheating (difference evaluation)
Difference in temperature values between surface sensor and control overheating sensor is too large. (Prerequisite for this trouble
code display is that the heater is in operation and the water temperature at the overheating sensor has reached min. 80C)
Check cooling system
if necessary
15
Overheating (operating block)
The controller is locked.

Delete the fault memory to release the controller
if necessary
16
Difference evaluation 2
If the surface sensor has a far higher temperature value than the control overheating sensor, then the system proceeds with a fault shutdown.
17
Overheating (hardware, device)
Temperature at control overheating sensor > 125C

Check the temperature sensor and overheating sensor,replace
if necessary
20
Glow plug interruption
Check cable harness for this component for damage and

through current and replace component if necessary
Check plug-in connection, replace component if necessary
21
Overload, short-circuit or ground

contact, glow plug output
Check cable harness for this component for damage, replace

component if necessary
22
Glow plug output defect
Check cable harness for this component for damage, replace

component if necessary
25
Comunication line short
Check the line
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
28
3B
Trouble
Code
30
Trouble Description
Remedies
Speed of combustion fan motor outside tolerable range
Fan wheel or combustion air fan motor blocked (frozen,

contaminated, stiff, cable harness scrapes on shaft end, )
Eliminate blockage
Measure speed of combustion air fan motor:
- dismantle combustion air fan
- check with 8.2 V + 0.2 V, to do so, unclip the cable 0.752
black from chamber 13 of the 14-pin connector and the
cable 0.752 brown from chamber 14. Apply marking (white
paint) to the fan wheel and measure speed with contactless
speed meter.
If the measured speed is outside a range of 8,800 rpm to
10,400 rpm, then replace the combustion fan. If the measured speed is within a range of 8800 rpm to 10400 rpm,
then replace the controller.
31
Burner motor interruption
Check cable harness for this component for damage and

through current
Check plug-in connection, replace component if necessary
32

contact, burner motor
Fan wheel or combustion air fan motor blocked

(contaminated, stiff)
Check cable harness of this component for damage, if necessary replace component
34
Burner motor output defect
Check whether the lead to this component has a short-circuit

to GND, if not, check component for ground contact, if necessary replace controller
47

contact, fuel pump
Check cable harness to the external component for damage

and through current and replace external component if necessary
48
Fuel pump interruption
Check cable harness to the external component for damage

and through current
Check plug-in connection, replace external component if
necessary
49
Fuel pump output defect
Check whether lead to this component has short-circuit to

+Ub, if not, check component for ground contact, replace
controller if necessary
50
Operating block because too many

start attempts in vain (10 start
attempts, also one start repeat for
every start attempt)
Too many start attempts, the controller is locked
Time exceeded for cold blowing
During start (no flame formed yet), the flame sensor reports
temperature value too high for too long
51
Delete the fault memory to release the controller

Check fuel quantity and fuel supply
Check exhaust and combustion air

Check flame sensor
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
Trouble
Code
52
29
Trouble Description
Safety time exceeded
Remedies
Check exhaust and combustion air system
Clean or replace sieve used in fitting of fuel pump
53
Flame aborted from power stage
54
Flame aborted from large stage
56
Flame aborted from small stage
Warning
In the case of flame aborted in power, large and small
stage and with still tolerable start attempts, the heater proceeds
with a new start or with subsequent start repeat. If the new
start or start repeat is successful, the trouble code display goes
off.
Fault(because no more start attempt allowed )
Check exhaust and combustion air system
Check flame sensor - see trouble code 64 and 65
60
Control overheating sensor interruption
Check cable harness to this component for damage and through

current
Check plug-in connection
Check sensor resistance value, replace component if necessary
61
64
Short circuit or ground contact control overheating sensor
Check cable harness to this component for damage
Flame sensor interruption
Check cable harness to this component for damage and

through current
Check sensor resistance value, replace external component if

necessary

65
Short circuit flame sensor

necessary
71
Surface sensor interruption
Check cable harness to this component for damage and through

current
72
Short circuit surface sensor

necessary
74
Overheating hardware defect, operating

block
Replace controller
87
Internal temperature sensor short-circuit
Replace controller
88
Internal temperature sensor interruption
Replace controller
89
CAN error
Check CAN interface
90
Watch dog reset
Replace controller
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
30
3B
Trouble
Code
Trouble Description
Remedies
91
Too many resets
Replace controller
92
ROM error
Replace controller
93
RAM error
Replace controller
94
Transistor fault occurs too frequently

- operation block
Remedy short-circuit of the component to +Ub to GND, replace

controller if necessary
95
Software stack overflow
Replace controller
96
No valid process, operation lock
Replace controller
97
Resonator/quartz faulty,
wrong processor cycle
Replace controller
98
Main relay faulty
Replace controller
99
EEPROM error
Replace controller
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
31
General Trouble Causes and Remedies

Condition
Low coolant
level
Abnormally
high coolant
temperature
Abnormally
loow coolant
temperature
Causes
Remedies
Coolant leakage
Change the radiatior
Leakage in coolant auxiliary tank
Change the coolant auxiliary tank
Leakage in heater core
Change heater core
Leakage in joint junction of coolant hose
Check the condition of hose and changing clamp
Leakage in defective coolant hose
Change the hose
Leakage in water pump gasket
Change the gasket
Leakage in water pump sealing
Change the water pump
Leakage in water inlet cap
Change the water inlet cap gasket
Leakagein thermostat housing
Change the thermostat sealing
Insufficient tightening torque of cylinder head bolt
Fasten the bolt to specified torque
Damaged cylinder head gasket
Change the head gasket
The coolant leakage (Check the coolant level)
Add coolant
excessive anti-freezer
Check the density coolant (Anti-freezer)
Bad coolant hose condition
Check the bent area of hose or change if needed
Defective themostat
Change thermostat
Defective water pump
Change water pump
Defective radiator
Change radiator
Defective coolant auxiliary tank or tank cap
Change coolant auxiliary tank or tank cap
Crack in cylinder head or in cylinder block
Change cylinder head or cylinder block
Clogged water flow in cylinder head or block
Clean the coolant flow line
Clogged water flow in radiator core
Clean the radiator core
Defective cooling fan
Change or check the cooling fan
Defective temp.sensor, wiring, and lamp cluster
Chaange the sensor and related area
Defective thermostat
Change the thermostat
Defective cooling fan
Change or check the cooling fan
Defective tem.sensor, wiring, and lamp cluster
Change the sensor and related area
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
32
3B
PTC (POSITIVE TEMPERATURE COEFFICIENT) SYSTEM

The supplementary electrical heater is installed in D27DT engine equipped vehicle as a basic equipment. The PTC
system is operated according to two temperature values measured at the coolant temperature sensor and HFM sensor.
This device is mounted in the heater air outlet and increase the temperature of air to the passenger room.
Because PTC system is heated by electrical power, high capacity alternator is required. (Alternator of 12V 75A/90A has
changed to 12V 140A)
Non-opeational Condition
- During engine cranking
- When too low battery voltage (Below 11V)
- During preheating process of glow plugs
Engine ECU
PTC Assembly
PTC Relay
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
33
2. PTC COMPONENTS
Radiator Element
Frame
Connector
Spring clip
PTC-Ceramic
Characteristics of PTC
P.T.C Heater
Heating type
Air heating type
Heating efficiency
Excellent
Element
Ceramic PTC (BaTio3)
Weight
approx. 500g
Durability
Excellent
Safety
Excellent
Advantages
- Stable output regardless of voltage changes

- Block the overcurrent with switch effect of PTC element
- High heating capacity in a moment
- Excellent durability of heating element against high current
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
34
3B
3. PTC OPERATING PROCESS

PTC Operating (ON) Condition
The operating condition of PTC is controlled by two step.
Generally, ECU control the power relay for PTC depending on the coolant temperature and ambient temperature sensor.
1st step (Initial PTC operating condition)
When coolant temperature < 15C, PTC is operating (ON).
When coolant temperature 15C, tow conditions decribed below must be satisfied.
2nd step (Coolant temperature: 15C)
When coolant temperature 65C and ambient temperature 10C PTC operates (ON)
When coolant temperature 65 ~ 60C and ambient temperature -10C ~ 0C PTC operates (ON)
When coolant temperature 60C and ambient temperature 0C ~ 5C, PTC operates (ON)
PTC OFF Condition

Airconditioner blower switch OFF
Ambient temperature sensor error (wiring short or open)
When engine craking
Battery voltage is lower than 11V
When preheating the engine (Glow indicator ON)
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
3B
35
Circit Diagram
FFH & PTC
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
36
3B

Preceding work: - Disconnect battery terminal (-)
- Remove I/P panel
1. Unscrew cable mounting bolt (1)
2. Disconnect PTC connector
3. Unscrew PTC mounting bolt and disassemble the PTC assembly.
CHANGED BY
FFH & PTC
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
4A
GENERAL INFORMATION
OVERVIEW
2WD
4WD
34: D27DT (2WD)

1.
7202700600
722 600 0
377900
DC Part Number Without Torque Converter
61: D27DT (4WD)
722 600 0
Blank
DC Variant Number
62: E3.2 Engine (4WD)
Engine Code Number
Serial Number
Transmission Type
2. Bar Code:
Automatic Transmission for

Passenger Car
3. Marked Number: 107 : 34 (D27DT, 2WD)
A/T Part Number
with Torque Converter
A/T Serial #
A/T Variant
105 : 61 (D27DT, 4WD)

100 : 62 (E3.2 GS1, 4WD)
DC 5-Speed Automatic Transmission

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

1. Improved shifting quality
2. More gears
3. Extended working life and reliability
4. Reduced fuel consumption
DC 5-SPEED AUTOMATIC TRANSMISSION
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4A
STRUCTURE
Basic structure of DC 5-speed automatic transmission
1. Torque converter
7. Disc brake B3
13. Freewheel F2
2. Oil pump
8. Disc clutch C3
14. Center planetary gear set
3. Input shaft
9. Disc brake B2
15. Electric control unit (valve body)
10. Output shaft
16. Freewheel F1
5. Disc clutch C1
11. Parking lock gear
17. Stator shaft
6. Disc clutch C2
12. Intermediate shaft
18. Converter lockup clutch
4. Disc brake B1
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
PERFORMANCE CURVE AND GENERAL CHARACTERISTICS

Standard mode
Vehicle speed (kph)
Lockup mode (open/sleeping)
Pedal value (%)
Vehicle speed (kph)
Vehicle speed (kph)
4-LOW mode
Pedal value (%)
Pedal value (%)
Note
1. Based on DI Engine + A/T equipped vehicle
specifications
Gear ratio
1st gear: 3.595
2nd gear: 2.185
3rd gear: 1.405
4th gear: 1.000
5th gear: 0.831
Rev. 1st gear: 3.167

Rev. 2nd gear: 1.926
Axle ratio: 3.31
2. WINTER Mode: Standard Mode

3. Allowable shifting point:
Upshift
Downshift
Lockup (sleeping)
Unlock (open)
FAST OFF
Dynamic shift range
STAVIC - 2004.09
4. FAST OFF
When abruptly releasing the accelerator pedal, the
transmission remains at 4th gear other than 4 4
shift (when slowly releasing the accelerator pedal, the
transmission is shifted to 5th gear).
5. Dynamic shift range
When operating the accelerator pedal, the 4 3 shift
is completed by kick-down signal after completion of
4 4 shift.
When promptly operating the accelerator pedal, the 4
3 shift is done in shaded arae.
CHANGED BY
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4A
SPECIFICATIONS
Item
W5A330 (300)
W5A580 (400)
330 Nm
580 Nm
78 kg
78 kg
270 mm
270 mm
Yes
Yes
1st
3.951
3.595
2nd
2.423
2.186
3rd
1.486
1.405
4th
1.000
1.000
5th
0.833
0.831
3.147/1.93
3.167/1.926
Input torque
Weight (including ATF)
Diameter (Torque converter)
Lockup function
Gear ratios
Reverse: S mode / W mode

Driving type
2WD (4WD)
Fuchs ATF 3353
Fluid specification
or Shell ATF 3353

Fluid capacity
Selector lever position
approx. 8
P.R.N.D
D+/D-
Mechanical
Electrical
Parking lock system
Brake switch (signa) TGS lever
Reverse lock system
CAN TGS lever
Selected lever indication
Oil temperature sensor
P.R.N.D
Lever position
4, 3, 2, 1
CAN
Resistance: R, D
0.5 ~ 2.5 k
Resistance: P, N
20 k
TCU
EGS 52
3.8 0.2
Shift solenoid valve
Resistance
(25C)
Operating distance
0.2 mm
Operating current
1.5 ~ 2 A
5.0 0.2
M/P, S/P solenoid valve
Resistance
(23C)
Operating distance
0.6 mm
Operating current
0~1A
Lockup solenoid valve
Resistance
(25C)
Operating distance
Operating current
Operating range
RPM sensor
Resistance
Operating voltage
Start lockout switch
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AFFECTED VIN
2.5 0.2
0.2 mm
1.5 ~ 2.0 A
3rd to 5th gears
HALL type
6V
Switch contact
ON (D, R position )
Switch contact
OFF (P, N position)

STAVIC - 2004.09
4A
7
Item
W5A330 (300)
Mode switch
W5A580 (400)
W (Winter)
S (Standard)
One-way clutch
F1, F2
Planetary gear set
Plain planetary gear: 3 (number of pinion)
Friction plates
C1, B1, B3
Single side friction plate
C2, C3, B2
Double side friction plate

STAVIC - 2004.09
3, 4, 3
4, 4, 4
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4A
POWER FLOW
Sectional View
Shifting elements
Gear
C1
C2
C3
B1
B2
3)
3)
5
P/N
1)
P/N
2)
2)
F1
F2
z
z
3)
z
z
R 1)
B3
z
z
3)
3)
1) Selector program switch: S mode

2) Selector program switch: W mode
3) Overrun
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STAVIC - 2004.09
4A
Engine torque
9
Torque
converter
lockup
clutch
Flywheel
Torque
converter
Automatic
transmission
Multiple disc
clutch
Multiple disc
brake

STAVIC - 2004.09
Final drive
gear
Output
torque
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AFFECTED VIN
10
4A
1st Gear (3.932)
Input
Output
E. 3rd gear ratio
M. Center planetary gear set
A. Engine speed
F. Mounting elements
P. Impeller
B. Transmission, input shaft
H. Rear planetary gear set
T. Turbine wheel
C. 1st gear ratio
L. Stator
V. Front planetary gear set
16. Torque converter lockup clutch
D. 2nd gear ratio
* Input shaft: Clockwise rotation

* Front sun gear: Locked by F1 and B1, Planetary gear carrier: Rotation with reduced speed
* Rear ring gear: Counterclockwise rotation
* Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed
* Center ring gear: Clockwise rotation
* Center sun gear: Locked by B2, Rotation with reduced speed
* Output shaft: Clockwise rotation
Gear
1
C1
C2
C3
B1
B2
3)
3)
B3
F1
F2
Lockup clutch
3) Overrun
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STAVIC - 2004.09
4A
11
2nd Gear (2.408)
Output
D. 2nd gear ratio
A. Engine speed
E. Mounting elements
P. Impeller
T. Turbine wheel
C. 1st gear ratio
L. Stator

* Sun gear and planetary gear carrier: Clockwise rotation by C1 activation
* Rear ring gear: Clockwise rotation
* Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed
* Center ring gear: Clockwise rotation
* Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed
Gear
C1
C2
C3
z
3)
B1
B2
B3
F1
3) Overrun

STAVIC - 2004.09
F2
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12
4A
3rd Gear (1.486)
Input
Output
D. Mounting elements
P. Impeller
A. Engine speed
T. Turbine wheel
L. Stator
C. 1st gear ratio

* Front ring gear: Clockwise rotation
* Center ring gear: Clockwise rotation by clutch 2 activation (direct connection)
* Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed
Gear
C1
C2
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C3
B1
B2
B3
F1
F2

STAVIC - 2004.09
4A
13
4th Gear (1.000)
Output
T. Turbine wheel
L. Stator
A. Engine speed
B. Planetary gear set
P. Impeller

* Center ring gear and rear planetary gear carrier: Clockwise rotation
* Front sun gear and planetary gear carrier: Clockwise rotation (direct connection)
* Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection)
* Center ring gear: Clockwise rotation by C3 activation
* Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection)
Gear
C1
C2
C3

STAVIC - 2004.09
B1
B2
B3
F1
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F2
14
4A
5th Gear (0.830)
Output
E. 3rd gear ratio
A. Engine speed
P. Impeller
T. Turbine wheel
C. 1st gear ratio
L. Stator
D. 2nd gear ratio

* Front sun gear: Locked, Planetary gear carrier: Rotation with reduced speed
* Rear planetary gear carrier: Clockwise rotation with reduced speed
* Center ring gear and rear planetary gear carrier: Clockwise rotation by clutch C2 activation
* Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear (increased
speed)
* Center sun gear: Clockwise rotation with increased speed by C3 activation
* Center planetary gear carrier: Clockwise rotation (increased speed)
* Output shaft: Clockwise rotation (increased speed)
Gear
5
C1
C2
C3
B1
3)
B2
B3
F1
F2
3) Overrun
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STAVIC - 2004.09
4A
15
Reverse 1st Gear (3.160, S Mode)
Input
Output
A. Engine speed
P. Impeller
T. Turbine wheel
C. 1st gear ratio
L. Stator
D. 2nd gear ratio

* Front sun gear: Locked by one-way clutch F1
* Front planetary gear carrier: Clockwise rotation (reduced speed)
* Rear planetary gear ring gear: Clockwise rotation
* Rear planetary gear carrier: Locked by B3
* Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
* Center ring gear: Locked by B3
* Center planetary gear carrier: Counterclockwise rotation (reduced speed)
* Output shaft: Counterclockwise rotation
Gear
C1
R (S)
C2
C3
B1
3)
B2
B3
F1
3) Overrun
STAVIC - 2004.09
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F2
16
4A
Reverse 2nd Gear (1.930, W Mode)
Input
Output
D. 2nd gear ratio
A. Engine speed
P. Impeller
T. Turbine wheel
C. 1st gear ratio
L. Stator

* Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection)
* Rear planetary gear carrier and center ring gear: Locked by brake B3
* Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
* Center planetary gear carrier: Counterclockwise rotation (reduced speed)
* Output shaft: Counterclockwise rotation
Gear
C1
R (W)
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C2
C3
z
B1
B2
B3
F1
F2

STAVIC - 2004.09
4A
17
FUNCTION AND DESCRIPTION

SELECTOR LEVER
P: Parking and starting position
This position is used when the vehicle is parking, starting the engine or stationing the vehicle. In this position, the driving
wheels are locked by parking pawl. To shift into any other positions, must depress the brake pedal (parking lock system).
R: Reverse driving
Conversion between Standard and Winter switch changes the reverse gear ratio but must be operated before the
selector lever is moved. Pressing on the Winter switch allows to have effective driving when driving on the slippery road
surface and, also, possible to have smooth driving in reverse as it starts in 2nd gear.
N: Neutral, starting and towing position

The engine can be started in this position. And, this position is used in temporary stop. If it is necessary to tow a vehicle,
use a professional tow truck service. If not available, use emergency towing by towing vehicle and lope. In this case, the
towing distance should be limited by 50 km with 50 km/h of towing speed.
D: All forward gears (1st ~ 5th)

This position is for all normal forward
driving in 1st to 5th gear. At 5th gear, the
gear ratio is 0.83:1. When driving forward at the speed of over 10 km/h, the
selector lever cannot be changed to P
or R position by parking reverse block
function.
4: Up shifting only up to 4th gear

In general, up to 4th gear is automatically shifted at the normal road driving
position. In D position, while driving,
pushing the lever in the left () direction
once makes down shift to 4th gear,
which is the same function as the O/D
OFF (Over Drive OFF) of normal vehicle.
3: Up shifting only up to 3rd gear

Automatically shifts up to only 3rd gear
and able to achieve engine brake effect
on long slope/down hill and, in D
position, pushing the lever in the left ()
direction twice makes down shift from
5th gear to 3rd gear.
1234D
-D+
1234D
2: Up shifting only up to 2nd gear

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

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

depress the location shown above picture
STAVIC - 2004.09
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18
4A
TORQUE CONVERTER
Function (4WD)
Torque converter is installed between engine and automatic transmission. It consists of pump impeller, turbine and
stator. The pump impeller is welded at converter housing and the converter housing is bolted at the drive plate.
The torque converter converts the mechanical energy from engine to hydraulic energy, and the turbine connected to
transmission input shaft converts this hydraulic energy to mechanical energy again. The stator between pump and
turbine increases the output torque from turbine by converting the flowing direction.
The stator has a torque converter area that changes the flowing direction and a fluid coupling area where the stator
rotates. And, the lockup clutch integrated in torque converter prevents the power from losing and reduces fuel consumption.
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STAVIC - 2004.09
4A
19
Installation and Inspection

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

converter.
[Notice]
Place the automatic transmission upright when removing
and installing torque converter.
If not, the oil seal may be damaged when servicing the torque
converter.
The distance between the upper end of torque converter

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

STAVIC - 2004.09
Engine
E23/E28/E32/D27DT
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20
4A
LOCKUP CLUTCH
1. Impeller wheel
10. Multiple disc clutch pack
2. Turbine wheel
11. Piston
3. Stator wheel
4. Stator shaft
A : Closed (lockup clutch activates)
5. Multiple disc clutch drum
B : Slipping
6. Multiple disc clutch hub
C : Open (lockup clutch deactivates)
7. Converter cover
n : Transmission output speed
8. One-way clutch
d : Accelerator pedal position
9. Input shaft
Lockup clutch consists of multiple disc clutches as shown

in the figure and is activated in 3th, 4th and 5th gears. The
aim of using torque converter lockup clutch is to reduce
the fuel consumption and exhaust gas emissions of the
vehicle by reducing torque converter slip. This stands in
contradiction to the ride comfort demands made on the
drive train with regard to its vibration behaviors. The task of
the electronic transmission control is therefore to close
the clutch in all driving situations relevant to fuel
consumption, if possible, and ensure that the engine vibrations are isolated from the drive train.
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The characteristic curves shown in the diagram illustrate

the different operating states of the torque converter lockup
clutch in relation to the accelerator pedal position and the
transmission output speed, plotted for one transmission
gear.
Variables influencing the states of the torque converter
lockup clutch:
1.
2.
3.
4.
5.
6.
Accelerator pedal movement

Uphill and downhill gradients
Transmission shift functions
Transmission oil temperature
Load conditions
Engine control influences

STAVIC - 2004.09
4A
21
Lockup Clutch Regulating Valve
Lockup clutch
Torque converter
output
Torque converter
input
Transmission
lubrication points
Torque converter lockup

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

STAVIC - 2004.09
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22
4A
PLANETARY GEAR SET
Ring gear
Pinion gear
Sun gear
Planetary gear carrier
Output
Input
Locked
Relatively high
step-down ratio
Relatively low
step-down ratio
Locked
Input
Output
Output
Direction reversal and

step-down ratio
Relatively high step-down ratio

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

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

Planet carrier locked
Sun gear driving (clockwise)
Planet gears driven (counterclockwise)
Ring gear driven (counterclockwise)
Gear ratio: teeth of sun gear / teeth of ring gear
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STAVIC - 2004.09
4A
23
MULTIPLE-DISC CLUTCH
1. Input shaft
C1c. Internally toothed disc carrier C1
M1. Middle sun gear
9. Externally toothed disc
C2a. Piston C2
M3. Middle planet carrier
10. Internally toothed disc
C2b. Externally toothed disc carrier C2
M4. Middle ring gear
H1. Rear sun gear
C3a. Piston C3
V1. Front sun gear
C1a. Piston C1
V3. Front planet carrier
C3c. Internally toothed disc carrier C3
V4. Front ring gear
Location
Three multiple-disc clutches, the front, middle and rear multiple-disc clutches K1, K2 and K3, are located in the planetary gear sets in the transmission housing.
Funtion and description
A multiple-disc clutch consists of a number of internally toothed discs (10) on an internally toothed disc carrier and
externally toothed discs (9) on an externally toothed disc carrier.
If the piston (C1a) on multiple-disc clutch K1 is subjected to oil pressure, it presses the internal and external discs of the
disc set together. The sun gear (V1) is locked with the planet carrier (V3) via the externally toothed disc carrier (C1b) and
the internally toothed disc carrier (C1c). The front planetary gear set is thus locked and turns as a closed unit. If the
multiple-disc clutch C2 is actuated via the piston (C2a), the piston compresses the disc set. The ring gear (V4) of the
front planetary gear set is locked with the ring gear (M4) of the middle planetary gear set via the externally toothed disc
carrier (K2b) and the middle planet carrier (M3) on which the internally toothed discs are seated. Ring gear (V4) and ring
gear (M4) turn at the same speed as the input shaft (1). If the multiple-disc clutch C3 is actuated via the piston (C3a), the
piston compresses the disc set. The sun gear (M1) of the middle planetary gear set is locked with the sun gear (H1) of
the rear planetary gear set via the externally toothed disc carrier (C3b) and the internally toothed disc carrier (C3c). Sun
gear (M1) and sun gear (H1) turn at the same speed.
STAVIC - 2004.09
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24
4A
FREEWHEEL
1. Outer race
A. Rotation direction A
2. Inner race
B. Rotation direction B
3. Locking elements
V1/H1. Front or rear sun gear
4. Locking element cage
Location
Freewheels are installed in the front planetary gear set between the sun gear and the stator shaft, and in the rear
planetary gear set between the sun gear and the intermediate shaft.
Function and description

The freewheel consists of an outer race (1), an inner race (2), a number of locking elements (3) and a cage (4) for these
locking elements.
If the inner race (2) of the freewheel is locked and the outer race (1) turns in direction A, the locking elements (3) adopt
a diagonal position on account of their special contours, allowing the freewheel function.
The outer race (1) slides over the locking elements (3) with negligible friction. If the rotation of the outer race (1) changes
to direction B, the locking elements (3) stand up and lock the outer and inner races (1, 2) together.
CHANGED BY
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STAVIC - 2004.09
4A
25
SENSORS AND CONTROLS

Components
Valve body assembly
1. Cap
5. Lockup PWM solenoid valve
2. Socket bolt (M6 x 32)
6. 2-3 shift solenoid valve
3. Socket bolt (M6 x 30)
7. Shift pressure (SP) solenoid valve

8. Modulating pressure (MP) solenoid valve
11. Electronic control module

12. Lockup clutch control solenoid valve
4. Leaf spring

STAVIC - 2004.09
9. 1-2/4-5 shift solenoid valve
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26
4A
Shift Pressure Control Solenoid Valve
1. Leaf spring
7. Solenoid valve
2. Contact spring
A. 1-2, 4-5 shift solenoid valve
3. Conductor track
B. 3-4 shift solenoid valve
4. O-ring
8. Solenoid valve
5. O-ring
C. Shift pressure control solenoid valve
6. Shift plate
D. Modulating pressure control solenoid valve

9. Solenoid valve
E. Lockup PWM solenoid valve
F. 2-3 shift solenoid valve
Function
The plastic Electric Hydraulic Control Unit (EHU) is installed on the top of valve body. RPM sensor, start lock-out switch
and oil temperature sensors are integrated in EHU.
The 13-pin connector is connected to automatic transmission via PCB.
Three up/downshift solenoid valves are installed on the top of hydraulic control unit.
The solenoid valves are sealed with two O-rings against the valve body. The solenoid valves are pressed against the valve
body by the leaf springs.
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STAVIC - 2004.09
4A
27
Characteristics of up/downshift solenoid valve

The solenoid valve remains energized and therefore open until
the shift process is completed according to the engine and
transmission conditions. If a solenoid valve is energized, it
opens and transmits shift valve pressure to the corresponding
command valve.
Working Current
1.5 ~ 2.0 A
Operating distance
0.2 mm
Resistance
3.8 0.2 (25C)
I (Current)
2.5A
1.5A
60mA
T (Time)
Circuit diagram
3-4 shift S/V
2-3 shift S/V

STAVIC - 2004.09
1-2, 4-5 shift S/V
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28
4A
Modulating Pressure (MP) and Shift Pressure (SP) Control Solenoid Valve
Solenoid valve
1. Leaf spring
4. MP control solenoid valve
2. Shift plate
5. SP control solenoid valve
3. Strainer
Function
These valves control the modulating pressure and the shift
pressure by applying appropriate electric current to solenoid valves according to driving condition of engine and
transmission.
Working Current
0 ~ 1.0 A
Operating distance
0.6 mm
Resistance
5 0.2 (25C)
When the electric current from TCU is high/low, the regulated pressure decreases/increases.
Regulated
pressure
Regulated pressure
Drain line
Drain line
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Line pressure

STAVIC - 2004.09
4A
29
Circuit diagram

STAVIC - 2004.09
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30
4A
Lockup Solenoid Valve
1. Leaf spring
3. Shift plate
2. O-ring
Function
This valve activates and releases the lockup clutch by
adjusting the current to solenoid valve according to engine
throttle opening value and output shaft speed. The lockup
clutch operates in 3rd, 4th and 5th gear with steps to reduce shift shocks.
Working Current
1.5 ~ 2.0 A
Operating distance
0.2 mm
Resistance
2.5 0.2 (25C)
Operating range
3, 4, 5 shift
Circuit diagram
Lockup S/V
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STAVIC - 2004.09
4A
31
Speed Sensor
Speed
sensor (n3)
1. Leaf spring
Speed
sensor (n2)
3. Pulse ring
2. Valve body
Function
The speed sensors are fixed to the shell of the hydraulic control unit via the contact tabs. A leaf spring, which rests
against the valve body, presses the speed sensors against the transmission housing. This ensures a precise distance
between speed sensors and impulse rings. speed sensor (n3) detects the speed of the front sun gear and speed sensor
(n2) detects the speed of the front planetary carrier. If the speed sensor is defective, the transmission is operated in
emergency driving mode. Below table shows the detection of speed sensor.
Gear
N2
N3
2
3
4
5
R (S mode)
R (W mode)

STAVIC - 2004.09
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32
4A
Circuit diagram
Speed
sensor
n3
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Speed
sensor
n2

STAVIC - 2004.09
4A
33
Oil Temperature Sensor
Function
The oil temperature sensor is installed in hydraulic control unit and is connected in series with the starter lock-out
contact.
This means that the temperature signal is transferred to TCU when the starter lock-out contact is closed.
The oil temperature has a considerable effect on the shifting time and therefore the shift quality. By measuring the oil
temperature, shift operations can be optimized in all temperature ranges.
Circuit diagram
Starter lock-out contact

AD converter

STAVIC - 2004.09
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34
4A
Starter Lock-out Contact Switch
1. Plunger
3. Reed contact
2. Permanent magnet
Function
The starter lock-out contact is installed beside oil temperature sensor and is actuated by a cam rail, which is located on
the latching plate.
In the selector lever positions P and N, the permanent magnet is moved away from the reed contact. This opens the
reed contact and the transmission control module receives an electrical signal. The transmission control module activates the starter lock-out relay module. This closes the electrical circuit to the starter in selector lever positions P and
N via the starter lock-out relay module. In other words, when the selector lever is in driving positions, the contact is
closed and the starter cannot be operated.
Circuit diagram
Ignition switch 50
Start lock-out contact
AD converter
Starter
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STAVIC - 2004.09
4A
35
Kick-down Control
Function
When the throttle valve is partially opened, the shifting point gets faster. When the throttle valve is widely opened,
shifting point is delayed because the system needs low speed gear with bigger driving force.
Kick-down control is a system that enables to get bigger driving force as the down shift occurs by suddenly increasing
the throttle openings during constant driving. It has no separate kick-down switch where the down shift operates when
a certain point (about 1 second) lapses after opening of full throttle. The signal recognition allows to send control signal
to TCU from engine ECU via CAN communication.
Circuit diagram
Accelerator pedal module

(
) : For gasoline engine

STAVIC - 2004.09
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36
4A
Mode Switch
Function
The mode switch is installed beside the selector lever and it has two modes of S mode (Standard
Mode) and W mode (Winter Mode).
- S mode is used in normal driving (starts off with 1st gear). TCU (Transmission Control Unit)
provides pleasant driving by changing the shifting pattern according to the driving habits
(downhill gripping: approx. 11 ~ 13.5 %)
- When W mode is selected, the Winter mode indicator in meter cluster comes on, and the
vehicle starts off with 2nd gear to achieve smooth starting on the icy or slippery road.
In winter mode, the up shift becomes faster and the down shift becomes slower for improving fuel consumption. The W
mode is automatically changed to S mode in full throttle or kick-down operation. The vehicle can starts off with 2nd
reverse gear (gear ratio: 1.92 ~ 1.93) when the W mode is selected. It is very useful on icy and slippery road. However,
in this case, the W switch should be selected before placing the selector lever to R position.
Even though W mode is selected, the vehicle starts off with 1st gear in following:
When the system recognizes the mode switch operation, the selector lever control unit sends the control signal TCU via
CAN communication.
1. When the selector lever is in 1 position.
2. When fully depressing the accelerator pedal or when starting off with kick-down condition.
Circuit diagram
Instrument panel
Selector lever control unit
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STAVIC - 2004.09
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37
Reverse/Parking (R/P) Lock System
12
1. Selector lever
7. Locking lever
2. Shift pattern display
8. Shift detene spring
3. Parking lock release flap
9. Potentiometer for detecting selector lever position
4. Selector lever control unit
10. Base body
5. Mode switch
11. Spring of shift detent mechanism
6. Locking disc
12. Solenoid valve
Function
Reverse (R) lock system is a safety system that prevents the selector lever from shifting to P or R position by
activating the solenoid valve when the selector lever unit determines that the vehicle speed exceeds 10 km/h by checking the speed signal from wheel speed sensor via CAN communication.
Parking (P) lock system uses the signals from brake switch other than conventional cable system to shift to other
positions. The wiring harness for detecting brake switch operation is connected to selector lever control unit.

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

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

11. Potentiometer for detecting
selector lever position
12. Intermediate lever
5. Base body
6. Mode switch
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STAVIC - 2004.09
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39
Function of parking (P) lock

The selector lever position P is locked whenever the R/P
locking solenoid is not actuated by selector lever control unit.
The prerequisites for this are as follows:
* No voltage supply to the selector lever control unit (Ignition
switch is not positioned to ON)
* Brake pedal not depressed
Under these conditions, the locking lever (8) is in the locking
position. The tab on lock lever (9) locks the locking disc (1). It
is not possible to shift the selector lever out of selector lever
position P.
1. Locking disc
7. R/P locking solenoid
2. Cam (P lock)
8. Locking lever
3. Cam (R lock)
9. Tab on lock lever (P lock)
4. Selector lever
10. Tab on lock lever (R lock)

11. Potentiometer for detecting
selector lever position
12. Intermediate lever
5. Base body
6. Mode switch
Parking Lock Mechanism

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

STAVIC - 2004.09
1. Detent plate
4. Parking lock pawl
2. Spring
5. Guide sleeve
3. Cone
6. Parking lock gear
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4A
Selector Lever Control Unit

Function
Selector lever control unit functions as follows:
A. Informing the selector levers position to other units via CAN.
B. Turning on the selector lever indicator while tail lamp is turning on.
C. Turning on the back-up lamp during reverse driving.
D. Operating the parking/reverse lock system.
Terminals
Pin No.
Use For
Selector lever unit power
CAN HI
CAN LO
Connected to HECU, ECU, TCU,

instrument panel etc.
Brake switch signal
Parking lock operation
Self diagnosis
Tail lamp
Back-up lamp power
10
Back-up lamp
Ground
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Remark
Turning on position indicator

STAVIC - 2004.09
4A
41
Circuit diagram
Ignition switch
Ignition switch
Tail lamp relay
Self diagnostic 10
Brake switch
Selector lever
control unit
Backup lamp
Instrument panel,
HECU, ECU

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42
4A
CAN (Controller Area Network )

Function
CAN input signal
CAN output signal
Accelerator pedal position
Selected gear
Wheel speed (all wheels)
Shifted status
Engine rpm, Engine torque
Lock-up clutch status
Coolant temperature
Automatic transmission
Downshift
Kick-down status
TCU
Speed control (constant)
Driving conditions
Meshed gear
Engine torque control
2nd gear start up control
Selector lever position
Dangerous status (changes to

emergency mode when
overloading, dangerous conditions,
and internal fault exists)
Odometer (I/P)
ATF Temperature
Selected gear in transfer case
Circuit diagram
Self diagnostic 11
Instrument panel
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Selector lever unit

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

STAVIC - 2004.09
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44
4A
TCU block diagram

Engine torque
M/P S/V
36
Max. Engine torque
S/P S/V
37
Engine power loss

Engine rpm
Engine
control
Power supply (valves)
38
ACC pedal position
1-2/4-5 gears S/V
14
Shift pattern changes
3-4 gears S/V
D 15
Engine control status
2-3 gears S/V
16
Engine torque
reduction
Lockup clutch S/V

17
Wheel speed (FR, FL)
Sensor power supply
I 13
Wheel speed (RR, RL)
HECU
Sol.
valve
Sensor fround
33
Sensor
Driving force control
A
Posi. Identifi. signal WO
Start signal
Starter
relay
Posi. Identifi. signal W1
Selector
angle

N2 speed
12
N3 speed
35
W/S mode signal input
T/M
Driving force controls
W/S mode indication
I/P
Selector lever indication
Diagnosis
Diag.
Conn.
Mileage
29
Parttime
TOD
25, 27
30
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P/N starting recognition
IGN1
TCU (EGS) ground
Power
ground
Selected T/C gear
TCCU
EFFECTIVE DATE
TCU (EGS) power

STAVIC - 2004.09
4A
45
Characteristics of TCU and Automatic Transmission (LHM: Limp-Home

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

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

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4A
Connector arrangement and pin functions
Connector A
Connector B
Connector A
Connector B
Pin No.
Description
Connected to
Diagnostic
Diagnostic connector pin No.11
Initiating the starter relay
Starter relay
12
RPM sensor N2
13-pin plug No.3
13
RPM sensor voltage supply
13-pin plug No.7
14
1-2, 4-5 solenoid valve
13-pin plug No.13
15
3-4 solenoid valve
13-pin plug No.9
16
2-3 solenoid valve
13-pin plug No.11
17
Lockup clutch solenoid valve
13-pin plug No.11
29
TCU voltage supply
30
Ground
33
RPM sensor ground
13-pin plug No.12
34
ATF temperature, Starter lock-out contact
13-pin plug No.4
35
RPM sensor N3
13-pin plug No.1
36
Modulating pressure solenoid valve
13-pin plug No.2
37
Shift pressure solenoid valve
13-pin plug No.10
38
Each solenoid valve voltage
13-pin plug No.6
CAN Low
ECM, HECU, selector lever unit, instrument panel
CAN High
ECM, HECU, selector lever unit, instrument panel
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STAVIC - 2004.09
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47
OTHER FUNCTIONS
OIL LEVEL CONTROL
Function
This is the function that closes the opening between oil chamber and planetary gear set chamber, so that the gear set
does not splash in oil if the oil level rises.
The lubricating oil flowing continuously out of the gear sets returns through the opening (2) into the oil chamber. If the oil
level rises, the oil forces the float (1) against the housing.
The float separates the oil chamber from the gear set chamber. The lubricating oil which escapes further from the gear
sets is thrown against the housing wall by the rotating parts and flows now through the upper opening (arrow) back into
the oil chamber.
Reduction of power losses and prevention of fluid loss from the transmission at high fluid level.
1. Float
A. Oil chamber
2. Opening
B. Planetary gear set chamber

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4A
Oil Check and Specification
Lock pin
Lock pin
Cap
Checking and adding Tip

A. Place the vehicle on level ground. Pull out the lock
pin and remove the cap (add 4 to 5 liter if oil has
been completely drained out).
B. Place the selector lever to P position. Start the
engine and leave it idling (add 2.5 liter if oil has been
completely drained out).
Automatic transmission fluid capacity and

specification
Fluid capacity
Specification
Approx. 8
Fuchs ATF 3353 or Shell ATF 3353
C. Warm the engine up while moving the selector lever

to all positions. Check if the oil temperature is approx.
80C with a scanner (apply the parking brake).
: Selector lever position - R or D
D. Check the oil level with oil dipstick while engine is
running in P position.
E. Check several times with attention, and add or drain
the oil as required.
[Notice]
1) Use only specified ATF oil.
2) Measure the ATF oil temperature as the shift lever is in
R or P.
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STAVIC - 2004.09
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49
SHIFT ROD ADJUSTMENT

Adjustment
1. Range lever
D. D range
2. Shift rod
P. P range
3. Selector lever
A. Disengage the shift rod from range lever and place the range lever at D position.
B. Place the selector lever at D position.
C. Insert the shift rod into range lever and tighten nut.
[Notice]
Lock the selector lever so that it will not move.
D. Check if the indication lamp in meter cluster indicates correct gear position while moving the selector lever to P,
R, N, and D position.
E. Check if the engine can be started at selector lever P or N position.
STAVIC - 2004.09
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50
4A
CIRCUIT DIAGRAM
Starter, Selector Lever, CAN Communication
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51
Solenoid, Oil Temperature Sensor, RPM Sensor (N2, N3)

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4A
TROUBLE CODE AND DIAGNOSIS

TROUBLE DIAGNOSIS WITH SCANNER
Scanner Diagnosis Procedure

1. Connect the scanner connector to the diagnostic socket.
3. Select [DIAGNOSTICS] in [MAIN MENU] screen and press [ENTER].
4. Select [STAVIC] in [VEHICLE SELECTION] screen and press and press [ENTER].
5. Select [TCU] in [CONTROL UNIT SELECTION] screen and press [ENTER].
6. Select [TROUBLE CODE] in [FUNCTION SELECTION] screen and press [ENTER].
7. Determine the DTC and locate the trouble cause.
[Reference]
Choose data list item to check sensors and other
informative data.
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53
TCU Coding for DC 5-Speed Automatic Transmission

If the TCU or automatic transmission has been replaced, the TCU should be coded with SCAN 100.
Entering the diagnosis procedures

1. Select 1] DIAGNSTICS and press
MENU.
2. Select 6] STAVIC and press

SELECTION screen.
3. Select 2] TCU and press

SELECTION screen.

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in MAIN
in VEHICLE
in CONTROL UNIT
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4A
4. Select 5] TCU CODING and press

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

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

ignition key to OFF position and then turn it ON again.
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STAVIC - 2004.09
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55
TCU SCN Coding

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

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

CVN is made by TCU inner coding algorithm to check any software change of TCU
Procedure
1. Vehicle selection
3. Select TCU SCN

STAVIC - 2004.09
2. Control unit selection
4. Select the vehicle
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56
5. Select Yes
4A
6. Ignition key off and on and then, wait 50 seconds

Going in to TCU original number mode.
7. Check the TCU SCN and CVN number

(CVN specified number will be distrubuted to you soon)
[Notice]
CVN number which is shown right after SCN coing is
not available.
Check only the CVN number which is taken after waiting
50seconds, after ingintion Key is turned to On from
Off.
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STAVIC - 2004.09
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57
DTC (Diagnosis Trouble Code) of DC5AT

Trouble
Code
P2000
Defectives
Faulty TCU internal watchdog test
Action
- Self-diagnosis with IGN ON.
- Cycle the IGN switch from OFF to ON. Check and replace TCU if the
trouble still exists.
P2001
P2002
Faulty TCU internal watchdog

function
- Self-diagnosis.
Faulty TCU external watchdog test
P2003
P2004
Faulty TCU external watchdog

function
- Self-diagnosis.
Faulty TCU Clock
- Self-diagnosis.
P2005
Faulty TCU RAM

P2006
Faulty TCU RAM CAN-Controller 1

P2007
Faulty TCU RAM CAN-Controller 2

P2008
Faulty TCU ROM

- When the TCU internal checksum is different from scanner checksum.
P200A
Faulty TCU EEPROM

P200B
Faulty TCU CPU (internal)
P200C
Faulty TCU program control
P2010
No TCU variant coding
- Self-diagnosis.
- Check harness contact.
- Self-diagnosis.
- Check harness contact.
- When the TCU coding is not exist.
- Check again after TCU coding.
P2011
Faulty TCU variant coding

- When the TCU coding is faulty.
- Check again after TCU coding.
P2012
Faulty TCU checksum

P2013
Faulty TCU (internally)


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

- Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN
OFF, then disconnect TCU connector).
P2102
Defective 2-3 shift solenoid valve
- When 2-3 shift solenoid valve is defective.

- Measure the resistance of 2-3 shift solenoid valve (turn the IGN OFF,
then disconnect TCU connector).
P2103
2-3 shift solenoid valve - short

- Triggered mechanical emergency mode when the defective is detected.
P2104
Defective 3-4 shift solenoid valve

P2105
3-4 shift solenoid valve - short

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59
Trouble
Code
Defectives
Action
P2106
Defective lockup clutch solenoid valve
- Measure the resistance of lockup clutch solenoid valve (turn the IGN
P2107
Defective modulator pressure solenoid valve
- Measure the resistance of modulator pressure solenoid valve (turn the

IGN OFF, then disconnect TCU connector).
P2108
Defective shift pressure solenoid

valve
- Measure the resistance of shift pressure solenoid valve (turn the IGN
Electrical error: Fixed at 2nd gear in D range.
P2200
Faulty rpm sensor N2 signal
- When the rpm sensor N2 detects 0 rpm of front sun gear speed.
TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P2203
Faulty rpm sensor N3 signal
- When the rpm sensor N3 detects 0 rpm of planetary gear carrier speed.
TCU connector terminal B6: rectangular wave signal
B8: signal ground
B13: 6V
P220A
Abnormal rpm sensor output signal

(N2, N3)
P2220
Oil temperature sensor - short
- When the rpm difference between rpm sensor N2 and N3 is over

150 rpm.
- Turn the IGN OFF, then disconnect TCU connector.
- Selector lever position: R or D
- Measure the resistance of oil temperature sensor.
P2221
Abnormal oil temperature sensor

signal


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60
4A
Trouble
Code
P2222
Defectives
Action
Abnormal oil temperature sensor signal - Turn the IGN OFF, then disconnect TCU connector.
P2300
Faulty CAN communication

- Check the communication line for open, short and contact.
- Measure the resistance of CAN line: B1, B2
Specified value: approx. 60
P2301
Faulty CAN communication

- Check the communication line for open, short and contact.
- Measure the resistance of CAN line: B1, B2
Specified value: approx. 60
P2310
CAN: Faulty brake system communication
- Check CAN communication line H and L.

- Check ABS/ESP unit.
P2311
CAN: Faulty ECU communication

- Check engine ECU.
P2312
CAN: Faulty ECU communication

- Check engine ECU.
P2313
CAN: Faulty selector lever control

communication

- Check selector lever.
P2315
CAN: Faulty instrument panel commu- - Check CAN communication line H and L.
nication
- Check instrument cluster.
P2317
CAN: Faulty communication between

TCCU/TOD and CAN

- Check TCCU/TOD unit.
P2330
CAN: Faulty brake system signal

P2331
CAN: Faulty ECU message

- Check engine ECU.
P2332
CAN: Faulty ECU message

- Check engine ECU.
P2333
CAN: Faulty selector lever signal

P2335
CAN: Faulty instrument cluster signal

- Check instrument cluster.
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STAVIC - 2004.09
4A
Trouble
Code
P2337
61
Defectives
CAN: Faulty TCCU/TOD
Action
P2400
CAN: Faulty rear RH wheel speed

sensor signal

Check wheel speed sensor connector.
Check the air gap between tooth wheel and wheel speed sensor.
Check tooth wheel installation. (specified air gap: 0.309~0.958 mm).
Check the numbers of tooth wheel: 48
P2401
CAN: Faulty rear LH wheel speed

sensor signal

Check tooth wheel installation. (specified air gap: 0.309~0.958 mm).
P2402
CAN: Faulty front RH wheel speed

sensor signal

Check tooth wheel installation. (specified air gap: 0.335~0.945 mm)
P2403
CAN: Faulty front LH wheel speed

sensor signal

Check tooth wheel installation. (specified air gap: 0.335~0.945 mm)
P2404
CAN: No brake signal

P2405
CAN: No accelerator pedal signal

- Check engine ECU.
P2406
CAN: No engine torque signal

- Check engine ECU.
P2407
CAN: No ESP signal

- Check engine ECU.
P2408
CAN: No minimum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.
P2409
CAN: No maxmum engine torque signal - Check CAN communication line H and L.
- Check engine ECU.

STAVIC - 2004.09
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62
Trouble
Code
P240A
4A
Defectives
CAN: No engine rpm signal
Action
- Check engine ECU.
P240B
CAN: No engine coolant temperature

signal

- Check engine ECU.
P240C
CAN: No selector lever position signal

P240D
CAN: No transfer case position signal

P2500
Invalid transmission gear ratio
- Cycle the IGN switch from OFF to ON. Check A/T system again after a
certain period of driving.
- If the trouble still exists, replace A/T assembly.
- To protect transmission, any shift is not available.
P2501
Excessive engine rpm

- Check engine ECU.
P2503
Current selected gear
P220B
Excessive N2, N3 rpm
- Check rpm sensor N2 and N3.
P2510
Torque converter lockup clutch stuck
- Check the hydraulic lines for leaks (valve No.22 in valve body).

- Check the resistanve of lockup clutch solenoid valve (Turn the

IGN OFF, then disconnect TCU connector).
P2511
Faulty torque converter lockup heat

control
- Check the hydraulic lines for leaks.
P2520
Faulty recognition of torque reduction
- Check ECU.
P2502
Poor gear mesh, transmission slip
- Check the hydraulic lines for leaks.
P2600
Too low TCU supplying voltage
- Check TCU supplying voltage.
P2601
Too high TCU supplying voltage
- Check TCU supplying voltage.
P2602
Abnormal solenoid valve supplying

voltage
- Check solenoid supplying voltage.
P2603
Abnormal speed sensor supplying

voltage
- Check speed sensor supplying voltage.
- Check oil filter.
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TCU connector terminals B13: 6V

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63
HYDRAULIC SYSTEM
STRUCTURE OF VALVE BODY
Torque converter
Oil pump
Input shaft
B1 C1 C2 B3 C3 B2
Output shaft
Parking lock gear

Intermediate shaft
F2
F1
Stator shaft
Center planetary gear

Valve body
Lockup clutch
1. Shift housing
2. 1-2/4-5 command valve
8. Shift valve pressure control valve

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

STAVIC - 2004.09
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4A
HYDRAULIC CIRCUIT
M/P S/V
S/P S/V
1-2/4-5 shift
S/V
3-4
shift
S/V
Lockup S/V 2-3 shift S/V
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EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
65
1. Selector valve
21. Shift valve pressure control valve
2. 2-3 overlap control valve
22. Lock-up clutch control valve
3. Lubricating pressure control valve
24. 2-3 shift valve
4. Operating pressure control valve
5. Holding pressure shift valve
6. Command valve
27. B 2 shift valve
7. 3-4 shift valve
28. Modulating pressure solenoid valve
29. Shift pressure solenoid valve
9. One-way throttle valve
30. 1-2/4-5 shift solenoid valve
10. Ball change over valve
32. Lock-up solenoid valve
12. Filter screen
50. Oil pump
14. 1-2/4-5 command valve
51. Oil cooler
15. 1-2/4-5 holding pressure shift valve
52. Oil pan
16. 1-2/4-5 shift valve
53. Oil filter
18. 1-2/4-5 overlap control valve
54. Oil sump

20. Regulating pressure control valve
p-A. Operating pressure
p-Sm. Lubricating pressure
p-KUB. Lock-up clutch operating pressure
p-RV. Control valve pressure
p-Mod. Modulating pressure
p-S/RMV. Solenoid valve shift pressure
p-S. Shift pressure
p-SV. Shift valve pressure
p-S/KUB. Lock-up clutch control pressure
Huile. Reserved oil

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
4A
Oil Pressure
Modulating pressure
control solenoid valve
Shift pressure control

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

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

STAVIC - 2004.09
4A
67
Lubricating Pressure (p-SM)

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

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

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

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

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

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
68
4A
Shift Groups
The hydraulic control range (including shift elements), which is responsible for the pressure distribution before, during
and after a gear change, is designated a shift group.
The hydraulic system consists of 3 shift groups.
A shift group can be in two phases.
Shift phase
Stationary phase
In the shift phase, a change takes place in one shift group of the engaged clutch/brake. The other two shift groups are
then in the stationary phase.
Shift group C1/B1 (gear change 1-2/4-5) is responsible for the up/down shifts 1-2/2-1 and 4-5/5-4.
It includes:
Clutch C1
Brake B1
Command valve
Holding pressure shift valve
1-2/4-5 shift solenoid valve
Pressure overlap control valve
1-2/4-5 shift solenoid valve
Shift group C2/C3 (gear change 2-3) is responsible for the up/down shifts 2-3/3-2.
It includes:
Clutch C2
Clutch C3
Command valve
2-3 shift solenoid valve
Pressure overlap control valve
Shift group C3/B2 (gear change 3-4) is responsible for the up/down shifts 3-4/4-3 and the engagement process.
It includes:
Clutch C3, 3-4 pressure overlap control valve
Brake B2, 3-4 shift solenoid valve
Brake B3
Command valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
75
STRUCTURE OF ELECTRO-HYDRAULIC CONTROL MODULE (SHIFT PLATE)
A. Adjusting valve: Operating pressure, Lubricating

pressure, 2-3 group overlap
C. 3-4 shift group

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

STAVIC - 2004.09
5. Plastic valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
76
4A
Left Section
1.
2.
3.
4.
5.
6.
7.
Shift housing
1-2/4-5 command valve
1-2/4-5 holding pressure shift valve
1-2/4-5 shift pressure shift valve
1-2/4-5 overlap control valve
Shift pressure control valve
Regulating pressure control valve
8.
9.
10.
11.
12.
13.
Shift valve pressure control valve

Torque converter lockup clutch control valve
2-3 shift pressure shift valve
2-3 command valve
2-3 holding pressure shift valve
Shift valve B2
Right Section
1. Valve housing
2. Selector valve
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN


8. 3-4 shift pressure shift valve
STAVIC - 2004.09
4A
77
Disassembly and Reassembly

1. Remove the leaf spring (5).
2. Remove the bolt (1).
Installation Notice
Tightening torque
8 Nm
3. Remove the shift housing (4) from valve housing (2).

[Notice]
Before installation, make sure to insert the dowel pin into
correct position.
4. Remove the sealing plate (3).

[Notice]
Be careful not to lose 4 plastic balls and 8 steel balls in shift
housing.
5. Unscrew the bolts from shift housing and valve housing

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

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
78
4A
REMOVAL AND INSTALLATION (DC 5-SPEED A/T)

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

STAVIC - 2004.09
4A
79

Transmission Assembly
Preceding Work: 1)
2)
3)
4)
*
Disconnect battery negative cable

Make sure the vehicle stand stable with safty wedge under tires
Put the shifting lever in N
Remove skid plate
Check point
Make sure that the oil cooler pipe hose is not twisted, oil cooler pipe (radiator side) is not clogged. If it is contaminated with foreign materials, thoroughly clean before replacing transmission assembly (This work is necessary
when removing and installing the radiator).

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
80
4A
1. Remove the front and rear propeller shaft from the transfer
case.
Bolt
No
Tightening torque
M17
81 ~ 89 Nm
M14
70 ~ 80 Nm
Front
Rear
Oil draining
If necessary, drain the oil. However, when removing or installing the transmission without any other processes, just add oil
excluding drainage.
Installation Notice
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14 Nm

STAVIC - 2004.09
4A
81
2. Disconnect T/C motor connector, T/M plug connector, T/M shift lever, air bleeder hose and other attachments.
1. T/C motor connector (1) & plug connector (2).
2. Air bleeder hose (3).
3. T/M shift lever.

* Locate the shift lever in N.
P
N

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
82
4A
3. Remove T/M oil return pipe (A), supply pipe (B), oil filler pipe (C) from T/M.
A. Oil return pipe
B. Oil supply pipe
C. Oil filler pipe
* Transmission Assembly
[Notice]
1. Collect the dropping oil from removed pipes in the oil collecter and seal the pipes with caps.
2. Be careful not to contaminate the body and work space.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
83
4. For easier removal, unscrew the stabilizer mounting bolts (B) and put it down to the sub frame.
5. Support the transmission with hydraulic jack.
A. Stabilizer bar link

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
84
4A
6. Unscrew the center cross member mounting bolts.
A.Center bolts-center cross frame (14 mm - 2 EA)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
B.Side bolts-center cross frame (14 mm - 8 EA)

STAVIC - 2004.09
4A
85
7. Unscrew the T/M insulator bracket bolts and remove the bracket.
8. Unscrew the transfer case mounting bolts (12 mm - 11 EA) and remove the T/C from the T/M.
Tightening torque
20 ~ 25 Nm

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
86
4A
9. Remove the torque converter hole cover and unscrew torque converter bolts one by one as rotating the engine crank
shaft clockwise. (14 mm - 6 EA)
20 ~ 25 Nm
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
87
10. Unscrew the mission housing bolts and drop the transmission slowly with hydraulic jack (17 mm - 8EA, Tightening
torque: 50 - 60 Nm)
[Notice]
Be careful not to drop the torque converter
11. Remove the torque converter with special tool.

[Notice]
When install the torque converter on the mission, apply
small amount of ATF oil to the input shaft & frange.

[Notice]
Add the ATF oil and check the oil lever.
Before reinstallation, clean the T/M and related
components.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
88
4A
Selector Lever Assembly

1. Separate the selector.
[Notice]
Place the selector lever at P position when removing
installing selector lever and wire cable.
A. Shift rod
: Remove the shift rod pin (1) and separate the shift
rod from selector lever
2. Remove the selector lever cover (1) and the center

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

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

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
89
DISASSEMBLY AND REASSEMBLY (DC 5-SPEED A/T)

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

STAVIC - 2004.09
Adaptor plug
(transmission wiring connection)
Torque converter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
90
4A
Friction Disc
Transmission
Friction Disc
C1
C2
C3
B1
B2
B3
Numbers
Single
Dual
Single
Single
Dual
Dual
face
face
face
face
face
face
Single
Dual
Single
Single
Dual
Dual
face
face
face
face
face
face
W5A300
Type
(G32D: 4WD)
W5A400
Numbers
(D27DT: 4WD)
Type
Remark
Tightening Torque
No.
Description
Tightening
Torque (Nm)
Remark
Oil drain plug (oil pan)
14
Heaxgon, 5 mm
Oil filler pipe (upper)
12 ~ 14
Oil filler pipe (lower)
7~8
Oil cooler pipe
30 ~ 38
Oil pan
T 30
Torque converter housing/oil pump
20
Transmission rear mounting bracket (both sides)
36 ~ 44
Transmission rear mounting bracket (center)
20
Torque converter bolt
42
10
Converter housing/engine
50 ~ 60
11
Converter housing/transmission housing
20
T 45
12
Valve body
T 30
13
Valve body side cover
T 30
14
Solenoid valve
15
12-Angle collar nut
200
12-Angle, each 30 mm
16
B2 housing bolt
16
T 45
17
Selector lever unit bolt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
91

Valve Body Assembly
5. Valve body
5-9. Solenoid valve
1. Guide bush
5-3. Pin
2. Drain plug
5-4. Plate leaf spring
3. Bolts
5-5. Bolts
5-11. Screw
4. Oil filter
5-6. Electric kit
5-12. Screw
5. Valve body
5-7. Solenoid valve
5-13. Bolts
5-1. Valve body assembly
5-8. Lifting solenoid valve
5-10. Plate spring
6. Oil pan
5-2. Body assembly

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
92
4A
Preceding work:
Install the transmission on the fixture stand.
[Note]
To eliminate unnecessary working time and process,

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

(7 mm - 1EA)
2. Unscrew the oil pan bolts and remove the oil pan (6).
Installation Notice
Tightening torque
8 Nm
3. Remove the oil filter.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
93
4. Unscrew the bolts and remove the valve body from

transmission housing.
Installation Notice
Tightening torque
8 Nm
5. Disassembly and reassemblt the valve body assembly.

5-1. Remove the solenoid valve cap.
5-2. Unscrew the bolts on solenoid valve and remove the leaf
springs.
Installation Notice
Tightening torque
8 Nm
[Notice]
The socket bolts do not have same length. Be careful not to
mix up.
5-3. Remove the solenoid valves from valve body.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
94
4A
[Notice]
1. Make sure to install the solenoid valves at correct

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

plate.
[Notice]
Correctly align the electronic control module onto the shift
plate by using two central pins when installing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
95
Converter Housing and Transmission Housing
Transmission housing
Converter housing assembly
1. Install the transmission assembly on the fixture stand.

Fixture stand 116 589 06 59 00
2. Remove the rear extension housing from transmission

housing.
Installation Notice
Tightening torque

STAVIC - 2004.09
30 ~ 35 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
96
4A
3. Stretch out the bent point in 12-sided collar nut on output

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

output shaft flange.
Installation Notice
Tightening torque
200 Nm
* Bend the collar nut to lock it during installation.
5. Remove the rear oil seal ring.
6. Remove the snap ring with snap ring pliers and remove
the washer.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
97
7. Remove the ball bearing from transmission housing.

Install the flare clamping pliers.
Install the puller onto inner bearing race.
Rotate the clamping pliers counterclockwise (arrow
direction) to tighten.
Puller 001 589 50 33 00
Collet chuck 140 589 06 34 00
Remove the ball bearing from transmission housing
with spanner.
8. Unscrew the socket bolts fastening converter housing

and transmission housing and remove the transmission
housing from converter housing.
Installation Notice
Tightening torque
20 Nm
[Note]
Slightly turn the transmission housing to left and right
direction to make the removal process easier.
[Notice]
Apply loctite to the bolts from T/C housing to T/M. (15EA)
No loctite to the bolts from T/M to T/C housing. (2EA)

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
98
4A
Converter Housing Assembly

Clutch C3
Clutch C2
Clutch C1
Brake B1
Oil pump
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
99
1. Remove the clutch C3 from converter housing assembly.
4. Remove the brake B1.

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

STAVIC - 2004.09
16 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
100
4A
4-2. Remove the bolts in converter housing.

Installation Notice
Tightening torque
8 Nm
4-3. Remove the brake B1 from converter housing.
4-4. Separate the plate from valve body.

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

Installation Notice
Tightening torque
20 Nm
[Notice]
Install two bolts on the opposite side of oil pump housing
and tap the surface of oil pump with plastic hammer to
remove it from converter housing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
101
5-1. Remove the pump gears (1, 2) from pump housing.
5-2. Check the radial seal ring (3), and replace if necessary.
5-3. Replace the O-ring (4) with new one.
[Notice]
Lubricate the pump gears (1, 2) before installation.
Place the pump gear (2) into pump housing and install the
pump gear (1) onto the pump housing chamber.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
102
4A
Transmission Housing Assembly
Parking lock gear
Brake B2
Brake B3
Snap ring
Components of selector lever
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
103
1. Install the transmission assembly on fixture stand.

Fixture stand 116 589 06 59 00
2. Remove the snap ring from transmission housing.
3. Remove the spring washer and disc pack B3 from

[Notice]
To make the removal easier, remove the disc pack B3 while
compressing it.
Check each disc for wear and burnt out.
4. Remove the fixing bolts for brake B2 from transmission

housing.
Installation Notice
Tightening torque

STAVIC - 2004.09
16 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
104
4A
5. Remove the disc brake B2 from transmission housing.
6. Remove the parking lock gear.
7. Remove the fixing bolts for range selector lever.

Installation Notice
Tightening torque
8 Nm
[Notice]
Check the sealing ring for damage.
8. Remove the range selector lever, rod and detent plate.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
105
9. Remove the snap rings from parking lock pawl.
10. Remove the pin from transmission housing.
11. Remove the parking lock pawl from transmission housing.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
106
4A
COMPONENTS OF EACH ASSEMBLY
Clutch C1
Clutch C2
Clutch C3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
107
Clutch C2
Clutch C3
1. Sealing ring in disc carrier
11. Front planetary gear set
24. Clutch C3
2. Piston
12. Gear wheel
25. Sealing ring
3. Sealing ring in piston
13. Snap ring
26. Piston
4. Return spring
14. Thrust bearing
27. Disc spring
5. Spring plate
15. Clutch C2 and input shaft
28. Snap ring
6. Snap ring
16. Piston
29. Disc pack
7. Disc and steel plate
17. Inner sealing ring in piston
30. Snap ring
8. Snap ring
18. Outer sealing in piston
9. Snap ring
19. Return spring
Clutch C1
10. One-way clutch F1

A. Oil gallery in clutch C1
20. Spring plate

21. Snap ring
23. Snap ring

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
108
4A
Multi-disc brake B1
Multi-disc brake B2
Multi-disc brake B1
Multi-disc brake B2
1. Disc brake B1
8. Disc carrier B2
15. Spring plate
2. Piston
9. Sealing ring
16. Snap ring
3. Return spring
10. Sealing ring
17. Piston guides in B2 and B3
4. Snap ring
11. Piston in B2
18. O-ring
5. Cushion spring
12. Sealing ring in piston guide ring
13. Sealing ring in piston guide ring
20. Snap ring
7. Snap ring
14. Return spring
21. Cushion plate
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
109
Rear gear set and center output shaft
Rear freewheel and rear hollow shaft
Rear gear set and center output shaft
Rear freewheel and rear hollow shaft
1. Output shaft in center gear set
12. Hollow shaft
2. Needle bearing
13. O-ring
3. Teflon ring
14. Snap ring
4. Thrust washer
15. Freewheel
5. Thrust needle bearing
16. Inner disc carrier and rear sun gear/clutch C3
6. Shim
17. Thrust needle bearing
7. Snap ring
18. Shim
8. Rear gear set
19. Snap ring
9. Thrust washer
10. Clutch C3
11. Rear hollow shaft
C. Oil outlet port in clutch C3
D. Oil inlet port in clutch C3

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
110
4A
MEASUREMENT AND ADJUSTMENT

Shaft Axial Clearance Adjust
1. Measure the clearance between the ball bearing and the
parking lock gear.
Place the measuring bridge on top of transmission
housing and measure the distance from the parking
lock gear (a) to the measuring bridge.
Measure the distance from measuring bridge to the
ball bearing groove on mating surface with gauge (b).
Adjust the axial play E with adjusting shim.
ex) Distance a
49.90 mm
Distance b
49.00 mm
Difference
0.90 mm
Axial play E
0.40 mm
Shim size
0.50 mm
Axial play (specified value)
0.3 ~ 0.5 mm
[Notice]
Select a proper thickness of shim:
0.2, 0.3, 0.4, 0.5 mm
2. Install a shim.
Measuring bridge 126 589 04 31 00
3. Insert the ball bearing into rear part of transmission

housing.
[Notice]
Measure the clearance between ball bearing (2) and snap
ring. Install the appropriate size of snap ring.
(2.0, 2.1, 2.2 mm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
111
4. Install the radial sealing with a tool.

Arbor 140 589 12 15 00

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
112
4A
Measurement of Disc Brake B1
(Figure 1)
(1) Sectional drawing of brake B1
6b
6c
6f
6h
69
70a
70b
70c
L
External disc carrier

Piston
Disc spring
Snap ring
Friction disc
External disc (1.8 mm)
Clearance
(2) Procedure
(Figure 2)
1. Soak new discs into ATF for one hour before installation.
2. Install the brake B1 discs with the order as shown in
(Figure 1).
3. Install the compressor (078) on external discs (70c) and
apply the 1200N of force to the disc pack. This force is
applied on the marking ring point (small arrow in figure
2). Do not apply excessive force.
4. Determine the clearance (L) at three points between
external disc (70c) and snap ring (6h) with feeler gauge.
The snap ring (6h) should be contacted to top of the
external disc carrier (6b) during installation.
5 adjust the clearance with proper snap rings if needed.
Specified clearance (L):
No. of single face friction disc
No. of dual face friction disc
- 2 : 2.2 ~ 2.6 mm
- 3 : 2.4 ~ 2.8 mm
- 4 : 2.6 ~ 3.0 mm
- 2.3 ~ 2.7 mm
- 2.7 ~ 3.1 mm
- 3.0 ~ 3.4 mm
Thickness of B1 snap ring: 2.6, 2.9, 3.2, 3.5, 3.8, 4.1 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
113
(Figure 1)
14a
27
134a
134b
134c
134d
134e
144a
L

Piston
Friction disc
Disc spring
Snap ring
Clearance
(2) Procedure
(Figure 2)
(Figure 1).
3. Install the compressor (078) on external discs (134a) and
external disc (134a) and snap ring (144a) with feeler gauge.
The snap ring (144a) should be contacted to top of the
external disc carrier (14a) during installation.
5. adjust the clearance with proper snap rings if needed.
Specified clearance (L): No. of friction disc

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

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
114
4A
(Figure 1)
2
14a
133a
133b
133c
133d
133e
133f
L
Automatic transmission housing

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

Thickness of B3 snap ring: 3.2, 3.5, 3.8, 4.1, 4.4, 4.7 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
115
Measurement of Disc Clutch C1
(Figure 1)
(1) Sectional drawing of clutch C1
83a
86
86b
89a
89b
89c
89d
90
L

Piston
Disc spring
Friction disc
Snap ring
Clearance
(2) Procedure
(Figure 2)
2. Install the brake C1 discs with the order as shown in

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

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
116
4A
(Figure 1)
100a
101
105a
105b
105c
105d
106
107
L

Piston
Friction disc
Snap ring
Disc spring
Clearance
(2) Procedure
(Figure 2)
(Figure 1).
external disc (105c) and snap ring (106) with feeler gauge.
The snap ring (106) should be contacted to top of the

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

STAVIC - 2004.09
4A
117
(Figure 1)
37
41a
41b
41c
44a
44c
44g
44h
L
Friction disc (2.1mm)

External disc (4.0mm)
Piston
Snap ring
Disc spring
Clearance
(2) Procedure
(Figure 2)
(Figure 1).
3. Install the compressor (078) on external discs (41a) and
external disc (41a) and snap ring (44g) with feeler gauge.
The snap ring (44g) should be contacted to top of the
- 3 : 2.3 ~ 2.7 mm
- 4 : 2.4 ~ 2.8 mm
- 5 : 2.5 ~ 2.9 mm
- 2.3 ~ 2.7 mm
- 2.4 ~ 2.8 mm
- 2.5 ~ 2.9 mm
Thickness of C3 snap ring: 2.0, 2.3, 2.6, 2.9, 3.2, 3.5 mm

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
118
4A
[Notice]
* Free play of each disc - This value is measured by special

tool(208 589 00 21 00)
- Exept B3
Component
Number of friction plate
Single side disk
No single side disk
2.4 - 2.8 mm
2.7 - 3.1 mm
2.6 - 3.0 mm
3.0 - 3.4 mm
2.8 - 3.2 mm
3.3 - 3.7 mm
2.9 - 3.3 mm
3.6 - 4.0 mm
C1
C2
C3
B1
B2
B3
2.3 - 2.7 mm
2.4 - 2.8 mm
2.5 - 2.9 mm
2.7 - 3.1 mm
2.3 - 2.7 mm
2.3 - 2.7 mm
2.4 - 2.8 mm
2.4 - 2.8 mm
2.5 - 2.9 mm
2.5 - 2.9 mm
2.2 - 2.6 mm
2.3 - 2.7 mm
2.4 - 2.8 mm
2.7 - 3.1 mm
2.6 - 3.0 mm
3.0 - 3.4 mm
1.9 - 2.3 mm
2.0 - 2.5 mm
2.0 - 2.4 mm
1.0 - 1.4 mm
1.0 - 1.4 mm
1.0 - 1.4 mm
[Notice]
1) Approximately 1,200 Nm must be applied to keep the piston
down (B1, B2, C1, C2, C3)
2) 10 Nm is to be applied for B3
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
722.6
Shift member
119
Circlip thickness
in mm
C1
C2
C3
B1
B2
B3

STAVIC - 2004.09
Circlip part number
Clearance spec.
in mm
# frictions/spec
2.6
140 994 87 40
(3) 0.5 - 1.8
2.9
140 994 88 40
(4) 0.5 - 1.8
3.2
140 994 89 40
(5) 0.5 - 1.9
3.5
140 994 29 35
(6) 0.5 - 2.0
3.8
140 994 30 35
2.3
140 994 92 40
(3) 0.7 - 1.7
2.6
140 994 93 40
(4) 0.7 - 1.7
2.9
140 994 94 40
(5) 0.7 - 1.8
3.2
140 994 32 35
3.5
140 994 33 35
2.0
140 994 99 40
(3) 0.7 - 1.9
2.3
140 994 10 35
(4) 0.7 - 1.9
2.6
140 994 11 35
(5) 0.7 - 2.0
2.9
140 994 35 35
3.2
140 994 36 35
2.6
140 994 87 40
(2) 0.5 - 1.7
2.9
140 994 88 40
(3) 0.5 - 1.7
3.2
140 994 89 40
(4) 0.5 - 1.8
3.5
140 994 29 35
3.8
140 994 30 35
2.9
140 994 63 35
(4) 0.2 - 1.3
3.2
140 994 62 35
(5) 0.2 - 1.4
3.5
140 994 61 35
3.8
140 994 60 35
4.1
140 994 59 35
3.2
140 994 15 35
3.5
140 994 16 35
3.8
140 994 17 35
4.1
140 994 41 35
4.4
140 994 42 35
4.7
140 994 43 35
(ALL) 1.0 - 1.4
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
120
4A

Special Tool
W 126 589 01 62 00
Application
Removal and installation of torque converter
Handle
W 116 589 06 59 00
Fixing automatic transmission
Assembly stand
W 140 589 12 15 00
Installation of sealing ring
Arbor
W 001 589 50 33 00
Puller
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Removal and installation of

transmission housing ball housing

STAVIC - 2004.09
4A
121

W 140 589 34 63 00
Application
Fixing automatic transmission
Fixing plate
W 140 589 06 34 00
Removal and installation of transmission housing ball bearing
Collet chuck
W 140 589 13 43 00
Removal and installation of B1, B2, B3 piston
Piston puller
W 126 589 02 09 00
Socket

STAVIC - 2004.09
Removal and installation of

collar nut for output shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
122
4A
128 589 04 31 00
Measuring bridge
W 208 589 00 21 00
Application
Measuring the clearance between ball
bearing and parking lock gear
Compressing clutch and disc brake
Compressor
W 140 589 15 21 00
Measuring the oil level
Pipstick guage
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4A
123
Fixing Plate Assembly Stand W 140 589 34 63 00

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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4B
GENERAL INFORMATION
1. OVERVIEW
4WD
2WD
1. TSM54/52 transmission is designed to link the gear ratio, installation dimensions and shapes with current T5
transmission and BTRA automatic transmission. It provides maximum drivability by the optimized engine torque
and gear ratio.
2. TSM54/52 transmission uses linkage type shift elements directly connected to the transmission. It prevent the
transmission from shifting to the reverse gear from 5th gear when shifting to reverse gear. It also prevents the break
and wear.
TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
Features
3. All gears use the helical type and high strength
materials.
[Notice]
The helical type gear provides less noise.
4. The synchronizing devices are installed in 1/2,

3/4, 5/R gears. To prevent the double engagement,
the independent interlock devices are installed.
[Notice]
TSM54/52 transmission uses the inertia lock type key to
make smooth gear engagement and to provide silent gear
engagement.
5. The clutch release system is available to use CSC

(Concentric Slave Cylinder) or Fork type according
to the vehicle model. New Rexton uses the fork type
clutch release system.
6. The semi-remote control type gear shift mechanism
is used to prevent incorrect shifting.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
2. SPECIFICATIONS
General Specifications
Description
DI ENGINE
Length
(mm)
4WD: 628.3, 2WD: 672
Distance between shafts
(mm)
81
Input torque
(kgxm)
34.7 (340 Nm)
Transmission control type
Semi-remote
Weight (kg) - not including transmission fluid (kgxm)
4WD: 44, 2WD: 45
Gear ratio/Gear teeth
1st gear
4.315
(input gear: main gear)
2nd gear
2.475
3rd gear
1.536
4th gear
1.000
5th gear
0.807
Reverse gear
3.591
Specification
ATF DEXRON II or III
Transmission fluid
Capacity
Change interval
( )
4WD: 3.6, 2WD: 3.4

Inspect at every 10,000 km, replace at every
60,000 km (add or replace if necessary)
Tightening Torque
Description
Tightening Torque
Oil drain plug
4 ~ 5 kgfxm
39.22 ~ 49.03 Nm
Backup lamp switch (24mm)
3 ~ 4 kgfxm
29.42 ~ 39.22 Nm
Extension housing bolt (14mm)
4.2 ~ 5.7 kgfxm
41.18 ~ 55.89 Nm
Shift top cover bolt (12mm)
1.7 ~ 2.6 kgfxm
16.67 ~ 25.48 Nm
7 ~ 10 kgfxm
68.6 ~ 98 Nm
0.4 ~ 0.6 kgfxm
3.92 ~ 5.88 Nm
Extension housing spring plug (19mm)

Offset plate countersunk screw

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
3. SYSTEM COMPONENTS
Gear Combinations
1/2 shift fork
5/R shift fork
1st gear
3/4 shift fork
2nd gear
Input gear
Input shaft
Output shaft
5th gear
Counter shaft
3rd gear
4th gear
Shift Fork and Rail Combinations
Speedometer gear (2WD)
Transmission adaptor
Interlock plate
Reverse lock plate
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
Sectional View
4WD

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4B
1. Transmission front housing
38. Reverse idler gear
2. Input shaft oil seal
39. Reverse idler spacer
3. Front cover
40. Reverse idler bracket
4. Hexagon flange bolt (17 ~ 26 Nm)
41. Retainer ring
5. Oil drain plug
42. Reverse lock nut
6. Sealing
43. Transmission adaptor
7. Pin
44. Input shaft spacer
8. Input shaft
45. Counter spacer
9. Clutch 4th gear
46. Reverse needle bearing
10. Taper roller bearing (main)
47. Reverse gear
11. Taper roller bearing
48. Reverse clutch gear
12. Counter shaft
49. Reverse counter gear
13. Taper roller bearing (counter)
50. Synchro hub
14. Output shaft
51. Counter 5th gear
15. Inner race (reverse)
52. 5th needle bearing
16. Inner race (1st)
53. 5th gear
17. Needle bearing
54. 5th clutch gear
18. 1st gear
55. Thrust washer
19. 1st clutch gear
56. Spring pin
20. Synchro outer ring
57. 5th outside retainer ring
21. Synchro - middle cone
58. 5th retainer ring
22. Synchro inner ring
59. Counter shaft bushing
23. Synchro spring
60. Counter roller bearing assembly
24. Synchro key
61. Retainer ring
25. Synchro hub
62. Extension housing
26. Double synchro sleeve
63. Output shaft oil seal
27. 2nd gear
64. Offset plate
28. 3rd gear
65. Counter screw
29. 3rd clutch gear
66. Top cover
30. Synchro hub (3 & 4th)
67. Counter oil seal
31. Synchro ring (4/5/R)
68. Shift shaft
32. Single synchro sleeve
69. Shift lever
33. Retainer ring
70. Detent pin
34. Adaptor dowel pin
71. Joint pin
35. Reverse idler shaft
72. Retainer ring
36. Dowel pin
73. Semi remote lever assembly
37. Needle bearing
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
2WD

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4B
1. Transmission front housing
39. Reverse idler spacer
2. Input shaft oil seal
3. Front cover
41. Retainer ring
4. Hexagon flange bolt (17 ~ 26 Nm)
5. Oil drain plug
43. Transmission adaptor
6. Sealing
44. Input shaft spacer
7. Pin
45. Counter spacer
8. Input shaft
46. Reverse needle bearing
9. Clutch 4th gear
47. Reverse gear
10. Taper roller bearing (main)
48. Reverse clutch gear
49. Reverse counter gear
12. Counter shaft
50. Synchro hub
13. Taper roller bearing (counter)
51. Counter 5th gear
14. Output shaft
52. 5th needle bearing
15. Inner race (reverse)
53. 5th gear
16. Inner race (1st)
54. 5th clutch gear
17. Needle bearing
55. Thrust washer
18. 1st gear
56. Spring pin
19. 1st clutch gear
57. 5th outside retainer ring
20. Synchro outer ring
58. 5th retainer ring
21. Synchro - middle cone
59. Counter shaft bushing
22. Synchro inner ring
60. Counter roller bearing assembly
23. Synchro spring
61. Retainer ring
24. Synchro key
25. Synchro hub
63. Output shaft oil seal
26. Double synchro sleeve
64. Offset plate
27. 2nd gear
65. Counter screw
28. 3rd gear
66. Top cover
29. 3rd clutch gear
67. Counter oil seal
30. Synchro hub (3 & 4th)
68. Shift shaft
31. Synchro ring (4/5/R)
69. Shift lever
32. Single synchro sleeve
70. Detent pin
33. Retainer ring
71. Joint pin
34. Adaptor dowel pin
72. Retainer ring
73. Semi remote lever assembly
36. Dowel pin
74. Rear flange
37. Bearing
75. Ball bearing
76. Lock nut
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
11
Front View and Rear View

Front view
Rear view
1. Oil filler plug

(tightening torque: 40 ~ 50 Nm)
2. Shift rug (3 & 4th)
8. Interlock bolt
9. Shift lever
16. Reverse idler assembly

17. Spring pin (6 x 25)
10. Interlock plate
19. Backup lamp switch
4. Shift rug (5 & reverse)
11. Shift rail (1 & 2nd)
20. Concentric slave cylinder adaptor
5. Shift rail (5 & reverse)
12. Shift rug (1& 2nd)
6. Backup lamp switch
13. Shift fork (3 & 4th)
(8) Apply Loctite 243
14. Input shaft
(6) Apply Loctite DRI LOC 200

7. Shift rail (3 & 4th)

STAVIC - 2004.09
15. Counter shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4B
Cross Sectional Diagram of Major Components

Shift rail and 5/R gear
1/2 shift rail
5/R shift rail

3/4 shift rail
Offset lever
5. Apply Loctite DRI LOC 200
10. Apply Loctite 5900
A. Apply Long-term grease MoS2
1. Reverse lock spring
7. TGS bushing
13. Rolling plunger
2. Reverse lock plate
8. Outer spring pin
14. Return spring
3. Reverse lock bolt
9. TGS pin
15. Spring plug
4. Stopper plate
5. Air vent
6. Lock washer
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10. Lock bolt

11. Offset lever
12. Offset lever bushing
A. Apply Long-term grease MoS2

when installing the offset lever.

STAVIC - 2004.09
4B
13
Power Flows
1st gear
Counter shaft
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
2nd gear

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4B
Power Flows (Contd)

3rd gear
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
4th gear
4th
gear
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear

STAVIC - 2004.09
4B
15
Power Flows (Contd)

5th gear
4th
gear
3rd
gear
2nd
gear
1st Reverse
gear
gear
5th
gear
Reverse gear
Reverse
gear
4th
gear

STAVIC - 2004.09
3rd
gear
2nd
gear
1st Reverse
gear
idler
gear
5th
gear
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4B
4. SHIFTING MECHANISM
Interlock System
Interlock system prevents the gears from meshing over two sets.
Interlock bolt
Interlock plate
1/2
(3/4 & 5/R lock)
Inner shift lever
3/4
(1/2 & 5/R lock)
5/R
(1/2 & 3/4 lock)
Reverse Interlock System

Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward.
Neutral
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5/R select
5/R shift
5th gear disengaged

STAVIC - 2004.09
4B
17
Offset Lever and Rolling Plunger

To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear
selection gate after a gear has been selected.
1. Offset lever
3. Shift shaft
2. Shift lever
4. Rolling plunger (rolling plunger return spring and ball)

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4B
1. Shift check device

It determines the shift fork position (N or each gear) and
gives a detent movement to notice a shift lever seating
when operating the shift lever.
Detent pin
Adaptor - T/M
Also, it prevent the selected gear from getting out of its

meshed position.
3 & 4 Rall
Set ball
2. Gear jump out locking device

It prevents the shift lever is beyond the correct shift
position while shifting.
Hub spline
Sleeve spline
Clutch gear spline
3. Guiding a control direction and preventing an over stroke.
Offset lever
Offset plate
Backup Lamp Switch

It is normal open type switch. Its circuit is formed when the
reverse gear is selected.
[Notice]
Installation Notice
Sealant: Loctite DRI LOC 200
Tightening torque: 3 kgm ~ 4 kgm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
19
Synchronizer
Composition
It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each
other).
- 3/4 and 5/R shift: Single cone type
- 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner
cone and middle cone)
Single cone type
Double cone type
1/2 shift
1/2 shift
3/4 shift
3/4 shift
5/R shift
5/R shift
1. Synchronizer sleeve
5. Synchronizer key locking ring
2. Synchronizer hub
6. Synchronizer inner cone
3. Synchronizer ring
7. Synchronizer middle cone
4. Synchronizer key
[Notice]
Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve.
The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery).
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4B
Synchronizer element
A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to
prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning
and the clutch gear is spinning. Even though the clutch is disengaged, the clutch gear continues to spin until friction
slows it down or stops it. Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at
different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced and shifting effort is
lowered.
[1st step]
Sleeve
Synchronizer ring
Gear spline area
Projected area
Synchronizer key
Spline area of sleeve
Spline area of synchronizer ring
[2nd step]
Sleeve
Synchronizer ring
Gear spline area
Synchronizer key
[3rd step]
Sleeve

Synchronizer ring
Gear spline area
Synchronizer key
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
21
Bearing
The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in
Taper roller bearing

(input shaft, counter shaft and output shaft)
2. Needle bearings for 1/2 and 3/4 shift
Needle bearing
3. Needle bearing for reverse gear

(with cut out area)
4. Needle bearing for 5th gear
End Play of Taper Roller Bearing
1. Taper roller bearing for input shaft
A. End play A: 0.85 ~ 2.28 mm
2. Taper roller bearing for counter shaft
B. End play B: 1.17 ~ 1.97 mm
[Notice]
Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft.
(Specified range of end play: 0.05 ~ 0.1 mm)
For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 m)
For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 m)

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4B
Thrust Ring (Washer)

When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly
receives the axial force and this force acts as a resistance to rotating gears.
Input shaft
Thrust ring 1
3/4
synchronizer
5/R Thrust washer

synchronizer
1/2
synchronizer
Output shaft
Thrust washer
Counter gear assembly
Head set
gear
3rd
gear
2nd
gear
1st
gear
Reverse
gear
5th
gear
Lubrication
Transmission oil: ATF DEXRON II or III
Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease
Oil level
Oil drain screw
Installation Notice
Sealant on oil drain screw during installation: Loctite DRI LOC 200
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STAVIC - 2004.09
4B
23
2WD
4WD
1. Oil filler plug

2. Air vent
[Notice]
Sealant on oil drain screw during installation: Loctite DRI LOC 200

STAVIC - 2004.09
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24
4B
5. DIAGNOSTIC INFORMATION AND PROCEDURES

Trouble Diagnosis
Symptom
Cause
Action
Will not shift
Control lever assembly broken or damaged.
Replace control lever and housing assembly.
(control lever moves)
Damaged offset lever, shift fork, selector
Remove extension, adapter or case cover.
place or selector arm.
Check or replace damaged parts.
Hard shift or control lever
Clutch not releasing.
Adjust or replace clutch.
will not move into gear
Improper or low transmission oil.
Add or replace with specified oil.
Shift or shift rail binding.

Check or replace damaged parts.
Binding of sliding synchronizers or gears.

Check synchronizers and gears and replace
damaged parts.
If reverse only, faulty backup switch.
Check or replace backup switch.
Worn or damaged flywheel pilot bushing.
Replace pilot bushing.
Gears crash when shift-
Engine idle speed too high.
Adjust idle speed to specified speed.
ing
Damaged or faulty clutch.
Adjust or replace clutch.
Pilot bearing between input shaft and output
Replace or check roller bearings.
shaft binding.
Transmission jumps out
Damaged synchronizer.
Check or replace synchronizer parts.
Bell housing misaligned.
Align bell housing and bore.
Damaged gear(s).
Check or replace gear(s).
Worn or damaged flywheel pilot bushing.
Replace pilot bushing.
Loosened transmission or flywheel housing
Tighten bolts to specified value. Realign if
bolts, improper alignment.
necessary.
Synchronizer damaged or excessively worn.
Check or replace synchronizer parts.
Blocking ring damaged, worn index slots or
Check or replace blocking ring.
friction surfaces worn or damaged.

Excessive countershaft end play.
Check worn or damaged parts. Adjust shim

thickness using roller bearings if necessary.
Transmission locked in
Worn or damaged fork due to loosened shaft,
Check for wear or damaged. Replace worn
rail or shifting fork.
or damaged parts.
Fork or offset lever loose on shaft or rail.
Replace extension, adapter or case cover.
one gear
Check or replace loose parts on shaft or rail.

Replace roll pin(s).
Worn or damaged forks, offset lever, shaft
or rail.
Check for wear or damaged. Replace damaged parts.
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4B
25
Symptom
Transmission locked in
Cause
Worn or damaged synchronizer.
Action
Check worn or damaged synchronizer parts
and replace if necessary.
one gear
Worn or damaged gears.
Check worn or damaged gears and replace

if necessary.
Transmission noise
Improper or low transmission oil.
Add or drain and replace with proper oil.
Loose bolts or other attaching parts.
Tighten as specified.
Improper flywheel housing to engine crank-
Realign correctly.
shaft alignment.
Noisy transmission bearing.
Check bearings, bearing rollers and parts for

wear or damage. Replace if necessary.
Noisy gears.
Check for worn or damaged gears(including

speedometer gear). Replace if necessary.
Transmission leakage
Leakage from transmission.
Clean all exposed surfaces, then check for

leaks.
Vent or breather clogged.
Clean or replace vent or breather.
Too much oil.
Check oil level.
Loose bolts at sealing faces.
Tighten as specified.
Improperly applied sealant.
Clean leaking surfaces. Reapply sealant.
Worn or damaged oil seal.
Replace oil seal.

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4B
Diagnosis Table
Applicatio
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front
Possible Faulty Part
Transmission Case
Extension Housing
Shift Cover / Shift Shaft
Shift Control Lever
Input Bearing Retainer
Input Gear Set
3rd Speed Gear Set
2nd Speed Gear Set
Reverse Speed Gear Set
1st Speed Gear Set
5th Speed Gear Set
Clutch Housing and Release Derive
Crankshaft Pilot Bushing and Release Bearing
Input Bearing
Main Shaft Input Bearing
Main Shaft Thrust Bearing
3rd Speed Gear Bearing
2nd Speed Gear Bearing
1st Speed Gear Bearing
Reverse Idler Gear Bushing
Counter Shaft Front Bearing
Counter Shaft Rear Bearing
Counter Shaft Thrust Bearing
5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke Seal
Speedometer Drive / Driven Gears
Speedometer Driven Gear Housing
Input Shaft Seal
1 - 2 Synchronizer Assembly
3 - 4 Synchronizer Assembly
5th Synchronizer Assembly
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STAVIC - 2004.09
4B
27
6. CIRCUIT DIAGRAM (BACKUP LAMP)

STAVIC - 2004.09
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28
4B
ON-VEHICLE SERVICE
1. OIL CHECK/CHANGE
[Notice]
Do not check or change the oil Immediately after driving off.
It may cause serious hurt.
Place the vehicle on the flat and even ground and stop the
engine. After 5 minutes, check the oil level.
1. Remove the oil level plug (1) and check the oil level.
[Notice]
If the oil level is up to the bottom line of plug hole, it is OK.
1. Oil level check plug
2. If needed, add the oil through the oil level plug hole (1).
2. Oil drain plug
3. Fully tighten the plug and check the oil leaks.

4. If the oil level is up to the bottom line of plug hole, it is
OK.
[Notice]
The oil in manual transmission is major element for mechanical durability of transmission. Check the oil level with a
specific interval and add if needed.
The oil replacement should be done at the qualified and authorized service station.
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STAVIC - 2004.09
4B
29

4WD
Propeller shaft - Rear
Transfer case
Mounting insulator
Propeller shaft - Front
T/M assembly
Cross member -Center
2WD
Propeller shaft - Rear
Mounting insulator
T/M assembly

STAVIC - 2004.09
Cross member -Center
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4B

Preceding work: Disconnect the battery negative cable.
1. Remove the center cup holder assembly (1), shifting lever nob (2) and center console cover (3).
2. Unscrew the shifting lever mounting nut (A) and the shifting lever cover mounting nut (12 mm - 2 EA) (B).
Tightening torque
70 ~ 90 Nm
[Notice]
IIf the oil should be changed, remove the oil drain plug in
transmission housing and fully drain the oil. And, retighten
the plug.
Installation Notice
Tightening torque
40 ~ 50 Nm
3. Unscrew extension bar - sem remote mounting nut (1) and remove a pin (A) which connects the shifting lever and
extension rod.
Tightening torque
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70 ~ 90 Nm

STAVIC - 2004.09
4B
31
4. Unscrew 6 bolts at T/M output shaft flange, and fix the

propeller shaft on the body.
5. Disconnect the back up lamp switch connector and air bleeder hose from the T/M assembly.

STAVIC - 2004.09
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32
4B
6. Disconnect the clutch oil hose (Fix the hose with a tool to prevent oil leakage) at A marked position.
7. For easier work, unscrew three T/M housing bolts (1) and disconnect stabilizer bar from link (A) to have the
stabilizer bar down to sub frame.
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4B
33
8. Securely support the T/M with a hydraulic jack and then, remove center cross member.
- Center cross member mounting

bolts (A) (14 mm - 8EA)
- T/M mounting insulator bracket
bolts (B) (14 mm - 4EA)
9. Unscrew the T/M housing bolts.

Tightening torque

STAVIC - 2004.09
50 ~ 60 Nm
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34
4B
10. Drop the hydraulic jack with T/M slowly.

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STAVIC - 2004.09
4B
35
T/M ASSEMBLY
1. ASSEMBLY OVERVIEW
Top Cover Assembly
1. Top cover assembly - semi remote
7. Pin
13. Stud bolt
2. Nut
8. Joint housing
14. Bolt
9. Offset lever
15. Shift top cover
3. Remote shift lever

4. Shift boot - inner
10. Control housing arm insulator
16. Offset control lever
5. Snap ring
11. Semi remote kit assembly
17. Control shift spring
6. Lining shift socket
12. Shift rail

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36
4B
T/M Housing & Adaptor, Extension Housing
1. Front cover
10. Bolt
18. Shift lever rail-inner
26. 3rd/4th shift rail
2. Spacer
19. 1st/2nd shift fork
3. T/M housing
12. Oil seal
20. 3rd/4th shift fork
28. 5th/R shift rail
4. Filler plug
13. Rear cover
21. Inner lock plate
29. Spacer
5. Back up lamp S/W
14. Lock nut
22. Shift lug
30. Roller bearing
6. Drain plug
15. Rear flange
23. T/M adaptor
7. Adaptor
16. Bearing
24. 5th/R shift fork
8. Clutch cylinder
17. Shift lug
25. 1st/2nd shift rail
9. Pipe
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STAVIC - 2004.09
4B
37
Gear Assembly
1. Input shaft assembly
8. Synchronizer assembly (1st/2nd)
15. Taper bearing
2. 4th shift gear
9. Reverse shift gear
16. Counter gear assembly
3. Synchronizer assembly (3rd/4th)
10. Synchronizer assembly (5th/Reverse)
17. Retainer ring-counter

gear
4. 3rd shift gear
11. 5th shift gear
5. 2nd shift gear
12. Ball bearing
18. Taper bearing
6. Main shaft
13. Counter gear-5th
19. counter reverse spacer
7. 1st shift gear
14. Counter gear-Reverse

STAVIC - 2004.09
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38
4B
2. DISASSEMBLY
Preceding work: 1. Drain the T/M oil.
2. Remove the T/M from vehicle.
1. Remove the T/M top cover assembly.
[ 2WD Manual Transmission ]

1) Unscrew the rear flange lock nut (1) and bolts (2) to
remove rear flange.
2) Remove the T/M rear cover (A).
2. Remove the spring pin (6 x 25), as the offset lever pulled

side and remove the offset lever.
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STAVIC - 2004.09
4B
39
3. Remove the bolts from the extension housing.
4. Remove the extension housing with a special tool.

[Notice]
Remove the offset lever and rolling plunger with the extension
housing. Be careful not to drop them.
5. Remove the rear ball bearing with a puller and remove

the speedometer driven gear.
6. Remove the 5/R shift fork spring pin (6 x 28).

STAVIC - 2004.09
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40
4B
7. Pull the counter gear (5th gear) retainer ring out from the
ring groove with a ring pliers.
[Notice]
Be careful not to stiffen the retainer ring.
8. Spread the retainer ring and remove the counter 5th gear
with a puller.
9. Remove the counter reverse spacer.
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STAVIC - 2004.09
4B
41
10. Remove the 5th gear retainer ring with a ring pliers.
11. Remove the thrust washer from the shaft.
12. Remove the 5th gear and pull out the spring pin.
[Notice]
Be careful not to lose or mix the spring pins.
13. Remove the 5th gear needle bearings (2).

[Notice]
Be careful not to lose or mix the needle bearings.

STAVIC - 2004.09
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42
4B
14. Remove the 5th gear synchronizer ring.

[Notice]
Store at a safe place not to be mixed with other synchronizer
rings.
15. Remove 5/R gear retainer ring from the shaft with a ring
pliers.
[Notice]
Store the ring with the relevant gear to prevent incorrect
installation.
16. Remove the 5/R synchronizer hub assembly, the reverse

gear and the shift fork at a time.
17. Remove the counter reverse gear.
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STAVIC - 2004.09
4B
43
18. Remove the counter reverse gear needle bearing.

[Notice]
Store the needle bearing with the relevant gear.
19. Remove the interlock bolt.
20. Remove the transmission adaptor from the transmission

housing.
[Notice]
Be careful not to damage the adaptor mating surface.
21. Remove the gear assembly from the housing.

[Notice]
Do not forcefully remove the gear assembly. It may damage
the level grooves resulting in incorrect installation. Carefully
remove the gear assembly.

STAVIC - 2004.09
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44
4B
22. Remove the main and counter gear assembly.

Pull out the pins from 5/R and 1/2 shift rails and
remove the shift rails through rear section of adaptor.
Pull out the locking pins from shift forks.
23. Remove the shift rail and shift fork. Place the output shaft
and counter gear on the special tool.
24. Place the output shaft assembly with the 1st gear facing
down and remove the intermediate taper roller bearing
with a special tool.
[Notice]
To prevent the bearing damage, securely seat the special
tool before removing the intermediate taper roller bearing
that is pressed in.
Do not use general bearing puller.
25. Remove the 3/4 gear retainer ring.

[Notice]
Be careful not to lose or mix the retainer ring.
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STAVIC - 2004.09
4B
45
26. Remove the 3/4 gear synchronizer hub and single

synchronizer sleeve and 3rd gear with a special tool.
Pull out the needle bearing.
27. Loose the 1/2 gear and hub and double synchronizer
sleeve with a press.
28. Remove the reverse gear inner race.
29. Remove the main taper roller bearing.

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46
4B
30. Remove the inner race and 1st gear from 1st gear, and
remove the needle bearing from the shaft.
[Notice]
Store the disassembled gears by relevant components.
31. Remove the synchronizer inner intermediate cone and

outer ring in 1st gear side.
Synchronizer
under ring
Synchronizer
intermediate
cone
Synchronizer
outer ring
Synchronizer
outer ring
Synchronizer
intermediate
cone
Synchronizer
under ring
32. Remove the 1/2 gear synchronizer hub along with double
synchronizer sleeve.
33. Remove the synchronizer inner intermediate cone and

outer ring in 2nd gear side.
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STAVIC - 2004.09
4B
47
34. Remove the 2nd gear and needle bearing.
35. Remove the oil seal from the extension housing.

STAVIC - 2004.09
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48
4B
3. INSPECTION BEFORE REASSEMBLY

1. Clean all the disassembled components with solvent and
dry them with compressed air.
Check the components for crack, wear and damage.
Case, extension housing, shift lever
Input bearing retainer
Counter shaft rear bearing retainer
2. Check the bearing and shaft supporting area for wear
and replace if needed.
3. Check the surface conditions on:

Input shaft
Main shaft and gears
Counter shaft and 5th drive gear
4. Reverse idler shaft and gears

[Notice]
Replace the excessively worn components. Do not grind the
precisely machined components.
5. Check the following components for wear:

Selector arm
Interlock plate
1/2 and 3/4 shift fork
Shift shaft
Detent/guide plate and offset lever
Each shift lever shift fork
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STAVIC - 2004.09
4B
49
Hub and sleeve

1/2 shift fork, pads, synchronizer sleeve
3/4 shift fork, pads, synchronizer sleeve

5th gear shift rail/fork, pads, synchronizer sleeve
Reverse fork and reverse idler gear sleeve
6. Check the following components for excessive wear:

Crankshaft bushing in front of input shaft
Clutch release bearing
Main shaft pilot bearing roller
Main shaft thrust bearing mating surface
Main shaft speed gear roller bearing
Main shaft rear bearing
Counter shaft front and rear bearing
7. Check the gear sets for wear in teeth surface.

8. Check the gear sets for excessive wear, crack and break
and replace if needed.

STAVIC - 2004.09
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AFFECTED VIN
50
4B
9. Check the conditions of each synchronizer sleeve and

hub.
Engagement of hub and sleeve
Wear on cone clutch surface in blocking ring (brass)
engaging the gears
10. Measure the clearance between blocking ring and speed

gear.
New 1/2 gear blocking ring: 1.1 ~ 1.5 mm
New 3/4 gear blocking ring: 1.1 ~ 1.5 mm
[Notice]
If the clearance is excessive, replace it with new one. Otherwise,
it may cause the missing or breakage of the gears.
11. Check the speed gear clutch and synchronizer sleeve

for damage in teeth surface.
12. Check the engagement of synchronizer sleeve and speed
gear clutch.
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STAVIC - 2004.09
4B
51
4. REASSEMBLY
1. Install the 2nd gear needle bearing.
[Notice]
The 1st/2nd/3rd gear needle bearings have one bearing row
and the sizes of them are same. The reverse needle bearing
has two bearing rows. The 5th needle bearing is smaller than
others and consists of two bearings.
2. Install the 2nd gear and synchronizer outer ring,

intermediate cone and inner ring in regular sequence.
3. Insert three keys into 1/2 synchronizer hub and double

synchronizer sleeve. Install the synchronizer spring in
offset so that it should not be missed out.
[Notice]
Groove
1/2 gear double synchronizer sleeve doesnt have a step at

edge, however, 3/4 and 5/R gears have it.
No step

STAVIC - 2004.09
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52
4B
4. Install the 1/2 synchronizer hub and double synchronizer

sleeve into the output shaft by using a press.
[Notice]
Make sure that the hub groove faces to 2nd gear. Align the
synchronizer key and the synchronizer ring groove in 2nd
gear.
5. Install the synchronizer outer ring, intermediate cone and

inner ring in regular sequence.
6. Install the 1st gear.
7. Install the 1st gear needle bearing.
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STAVIC - 2004.09
4B
53
8. Install the 1st gear inner race by using a press.

[Notice]
The 1st inner race doesnt have a step at edge.
9. Install the main taper roller bearing by using a press.
10. Install the reverse fear inner race by using a press.

[Notice]
The reverse gear inner race has a step at edge.
11. Place the output shaft assembly with the 1st gear facing
downward and install the 3rd gear.

STAVIC - 2004.09
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54
4B
12. Install the 3rd gear.
13. Install the synchronizer ring on the 3rd gear.
14. Insert three keys into 3/4 synchronizer hub and

[Notice]
3/4 gear synchronizer sleeve have a step at edge. Place the
groove in hub to face the 3rd gear and align the synchronizer
key and the synchronizer ring groove in 3rd gear.
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STAVIC - 2004.09
4B
55
15. Install the 3/4 gear retainer ring.

[Notice]
Adjust the end play between retainer ring and hub to a range
of 0.05 to 0.1 mm by using a thickness gauge.
16. Install the intermediate taper roller bearing by using a

press.
[Notice]
Apply the force on the inner race other than other points.
17. Install the input shaft along with the 4th synchronizer
ring. Place the input shaft to face downward on the work
bench.

STAVIC - 2004.09
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AFFECTED VIN
56
4B
18. To relieve the load to the shaft bearing, insert a special

tool.
19. Place the counter gear on the work bench with the same
manner.
20. Install the transmission adaptor on the input shaft and

the counter gear.
21. Install the reverse gear needle bearing.

[Notice]
The reverse gear needle bearing has two bearing rows and
the others consist of two bearings.
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STAVIC - 2004.09
4B
57
22. Install the reverse gear in the shaft.
23. Install the synchronizer ring on the reverse gear.
24. Insert three keys into 5/R synchronizer hub and

[Notice]
Place the groove in hub to face the 5th gear and align the
synchronizer key and the synchronizer ring groove in reverse
gear.
25. Install the 5/R gear retainer ring.

Notice
[Notice]

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58
4B
26. Install the counter reverse gear by using a press.

[Notice]
Place the counter reverse gear with a longer protrusion facing
to the adaptor.
27. Install the counter reverse spacer.
28. Install the 5th synchronizer ring.
29. Install two 5th gear needle bearings in line.
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STAVIC - 2004.09
4B
59
30. Install the 5th gear.
31. Install the counter 5th gear by using a press. At this

time, place it with a longer protrusion facing to the adaptor.
32. Install the counter 5th gear retainer ring.
33. Install the locking ball.

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60
4B
34. Install the thrust washer (t= 5.0) while aligning the key
grooves.
35. Install the retainer ring.

[Notice]
36. Install the inner race of counter roller bearing by using a

press.
[Notice]
Place it with a protrusion facing to the adaptor
37. Place the gear assembly on a work bench in parallel.
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STAVIC - 2004.09
4B
38. Install the inner shift lever and interlock plate in the 3/4
gear shift rail.
61
Interlock plate
Inner shift lever
[Notice]
The spring pin for locking the inner shift lever is small (6 x
22) and its slot should face to the shaft.
39. Install the 3/4 hear shift rail in the transmission adaptor.
40. Install the 3/4 gear shift fork.

[Notice]
The 1/2 and 5/R shift fork are compatible, but 3/4 shift fork
isnt. Also, the 3/4 shift fork is chamfered, but 1/2 and 5/R
arent.
41. Install the 3/4 shift fork and shift rail while aligning the
grooves.

STAVIC - 2004.09
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AFFECTED VIN
62
4B
42. Install the 1/2 gear shift rail in the transmission adaptor.
43. Partially engage the 1/2 shift fork to the shift rail.
44. Install the shift lug on the 1/2 shift rail. Install the reverse
lock spring, reverse lock plate and reverse lock bolts.
[Notice]
Align the 1/2 gear shift lug and interlock plate mating surface.
45. Partially engage the 5/R gear shift fork to the shift rail.
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4B
63
46. Install the 5/R shift lug and 5/R shift fork on the shift rail.
[Notice]
Align the 5/R shift lug and the interlock plate surface.
47. Install the spring pin into the 1/2 shift lug. (intermediate
size: t= 6 x 25)
[Notice]
Place the spring pin with the pin slot facing to the shaft.
48. Install the spring pin into the 5/R shift lug. (intermediate
size: t= 6 x 25)
[Notice]
49. Install the spring pin into the 1/2 shift fork. (longer size:
t= 6 x 28)
[Notice]

STAVIC - 2004.09
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AFFECTED VIN
64
4B
50. Install the spring pin into the 5/R shift fork. (longer size:
t= 6 x 28)
[Notice]
51. Install the reverse lock plate and reverse lock spring on
the 1/2 shift rail.
52. Install the stopper plate on the 3/4 shift rail and insert the
spring pin. (intermediate size: t= 6 x 25)
[Notice]
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65
53. Apply the sealant to the transmission housing.

[Notice]
Sealant: LOCTITE 5900
54. Install the gear assembly and the adaptor to the

55. Install the speedometer driven gear on the output shaft
and install the ball bearing by using a press.
56. Apply the sealant to the extension housing. Press down

the extension housing against the adaptor.
[Notice]
Sealant: LOCTITE 5900

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66
4B
57. Tighten the extension housing bolts.

Tightening torque
42 ~ 57 Nm
58. Insert the offset lever into the 3/4 rail and install the spring
pin. (intermediate size: t= 6 x 25)
59. Apply the grease into the offset lever bushing.
60. Apply the grease to the interlock bolt and insert it into
the interlock plate hole and bolt hole.
[Notice]
Make sure that the gear is at neutral position. If not, the
interlock bolt cannot be inserted into the interlock plate
hole.
Sealant
LOCTITE 243
Tightening torque
40 ~ 50 Nm
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STAVIC - 2004.09
4B
67
Transmission Adaptor
1. Remove the reverse idler retainer ring.
2. Remove the components as follows and install in the

reverse order of removal.
Unscrew the reverse lock nut and idler bracket bolts
and remove the bracket and spacer.
Remove the reverse idler gear and the needle bearing.
Pull out the dowel pin and remove the reverse idler
shaft.
Installation Notice
Reverse idler bracket bolt
17 ~ 26 Nm
Reverse lock nut
70 ~ 100 Nm
Backup Lamp Switch

Remove the backup lamp switch with 24 mm wrench. Apply
the sealant when installing.
Installation Notice
Sealant
LOCTITE DRI LOC 200
Tightening torque
30 ~ 40 Nm

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
68
4B
INSPECTION/MAINTENANCE
SHIM ADJUSTMENT
1. Unscrew the bolts and remove the front fork cover.
[Notice]
The shim adjustment is necessary when replacing the
housings, counter gear, input shaft and output shaft.
2. Separate the front fork cover from the housing.
3. Remove the input spacer.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
69
4. Remove the counter spacer.
5. Prepare the special tools and dial gauge.
6. Place the transmission with the output shaft facing

downward and set the special tool on the counter gear
and input shaft. Apply a proper force to the counter gear
and input shaft so that the end plays for bearings are
maximized.
7. Tighten the adjusting bolt on the special toll to hold the

bearings.

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
70
4B
8. Set up the dial gauge on the transmission housing surface

and put the gauge needle to 0 point.
9. Put the probe end of the gauge on the taper roller bearing
outer race in counter gear and measure the end play.
* If the measured value is out of the specified range,
adjust it by using spacers.
End play
0 ~ 0.05 mm
10. Put the probe end of the gauge on the main taper roller
bearing outer race and measure the end play.
* If the measured value is out of the specified range,
adjust it by using spacers
End play
0 ~ 0.05 mm
11. Apply the sealant to the front fork cover and tighten the
bolts. Measure the starting torque after installation.
Starting torque
20 ~ 25 Nm
Sealant
LOCTITE 5900
Tightening torque
17 ~ 26 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN

STAVIC - 2004.09
4B
71

661 589 04 62 00 (W 99 31 007 0B)
Application
Removal/installation of transmission
Transmission fixture
W 99 31 001 1B
Removal of pressed in taper roller bearing
Bearing puller
W 99 31 002 1B
Pressing of the bearing and gear
Pressure pipe
W 99 31 003 1B
Insert key

STAVIC - 2004.09
Providing a space to input shaft

bearing
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
72
4B

W 99 31 004 1B
Die
W 99 31 005 2B
Holder
W 99 31 006 1B
Dial gauge holder
W 99 31 007 1B
Drift
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Application
Assembly of gears and bearings on
the shafts
Measurement of taper roller

bearing end play
Measurement of taper roller

bearing end play
Removal of 5/R synchronizer hub

assembly, reverse gear and shift fork

STAVIC - 2004.09
4C
GENERAL INFORMATION
1. OVERVIEW
Driving Elements
Operating Elements
The driving elements consist of two flat surfaces machined

to a smooth finish.
The clutch control system consists of the clutch pedal,

clutch master cylinder, concentric slave cylinder.
One of these is the rear face of the engine flywheel and

the other is the clutch cover pressure plate. The clutch
pressure plate is fitted into a clutch steel cover, which is
bolted to the flywheel.
This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases
the clutch by using release lever and release fork.
Driven Elements
This system provides higher efficiency than conventional

clutch system, and its durability is superior.
The driven element is the clutch disc with a splined hub

which is free to slide lengthwise along the splines of the
input shaft.
Adaptor (mounted on transmission case)
The driving and driven elements are held in contact by

spring pressure. This pressure is exerted by a diaphragm
spring in the clutch cover pressure plate assembly.
Concentric slave cylinder (mounted inside of transmission)
Concentric slave cylinder pipe (mounted inside of

transmission)
B. Concentric slave cylinder pipe
A. Adaptor
D. Clutch assembly
CLUTCH ASSEMBLY
STAVIC - 2004.09
C. Concentric slave cylinder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4C
SAT (Self Adjusting Technology)

: SAT is new clutch which adjusts the clutch free play according to the wearness of clutch disc.
Operation description
Diaphram spring rotates the adjusting equipment as clutch disc is wearing and so, pressure plate is pushed to clutch
disc side at the amount of wearness.
* Disc wear (Free play) Diaphram spring (1) Adjusting equipment (2, 3) Pressure plate (4)
Clutch assembly
Adjusting equipment
Clutch replacement
1) Replacement of cluch disc Replace the clutch cover assembly together.
2) Reinstallation of clutch disc & cover Apply the zig set (SST) on the clutch cover set.
(Engine removal and reinstallation, Flywheel related job, Checking the clutch assy)
[Notice]
When reinstall the clutch assembly without the special zig, Disc can be slip and worn easily.
Installation of special zig

1) Identify the SAT clutch with adjusting equipment around the clutch cover.
2) Adapt the zig set(4 pieces) between the clutch cover and diaphram spring around (Refer to the picture).
Diaphram
Adjusting
equipment
Cover
Zig for clutch removal

and installation
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
2. COMPONENTS
1. Concentric slave cylinder cover
7. Hose
12. Clutch housing
2. Concentric slave cylinder
8. Pipe
13. Switch
3. Clutch cover
9. Clutch fluid chamber
14. Bracket
4. Clutch disk
10. Clutch hydraulic line
15. Clutch pedal
5. Adaptor
11. Clutch pin (B)
16. Clutch pedal pad
6. Clutch master cylinder
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4C
Clutch Fluid Reservoir Tank

(Common Usage with Brake Oil Reservoir Tanks)
Clutch / Brake fluid

reservoir tank
Operation
Clutch pedal
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Pusha rod
Clutch master
cylinder
Concentric
(piston) slave
cylinder
Clutch cover
Clutch disk
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
Clutch Release Chamber

Clutch release chamber keeps the oil pressure stable in the clutch hose & pipe and also helps the oil pressure
transfer quickly by keeping some oil pressure every moments.
Clutch Pedal
Clutch pedal
Pendant type clutch pedal (leverage effect is applied to reduce the effort to the feet).
Clutch pedal has freeplay to prevent the clutch disk heated and damaged.
If this freeplay is too wide, engine power disconnection is difficult and arise the gear damage with abnormal noise.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4C
Clutch Assembly
Clutch assembly is composed of clutch cover (diaphram spring, pressure plate), clutch disk.
[Notice]
Because self adjust clutch includes compensation function
to make up for the wearness of clutch disk, this clutch
assembly applied to the vehicle can be oprated with constant
force in the clutch pedal.
Clutch disk connect the power from engine flywheel to the

transmission input shaft by the diaphram spring
compressing the clutch disk which has spline in the middle
frinction disk.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
Cross Sectional View of Clutch Assembly
1. Transmission housing
4. Bolt
2. Clutch disc assembly
5. Washer
3. Clutch disc cover assembly
6. Bolt
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4C
Specifications
Description
Specification
Operating type
Hydraulic
Clutch pedal
Suspended
Type
Maximum pedal stroke
Diesel engine equipped vehicle: 140 mm

Gasoline engine equipped vehicle: 150 mm
5 ~ 10 mm
Pedal free play

Clutch disc
Type
Single dry diaphragm
Dimension of facing
240 X 155 X 4.0 mm
Facing size/quantity
263 cm2/2
Thickness of disc
Free: 9.4 ~ 10.0 mm

When loaded: 9.0 0.3 mm
Min. 720kgf
Clutch cover assembly setting force

Clutch master cylinder
28.4 mm
Stroke
17.46 mm
Inner diameter
Concentric slave cylinder
7.0 mm
Stroke
706.2 mm2
Sectional area
DOT 4
Clutch fluid
Tightening Torque
Description
Tightening Torque
Clutch housing bolt (8 locations)
5.0 ~ 6.0 kgfm
50 ~ 60 Nm
Clutch cover (pressure plate) bolt
2.1 ~ 2.7 kgfm
21 ~ 27 Nm
Concentric slave cylinder bolt (3 locations)
1.7 ~ 2.6 kgfm
17 ~ 26 Nm
Concentric slave cylinder flare nut
2.0 ~ 2.5 kgf m
20 ~ 25 Nm
Adaptor flare nut
1.0 ~ 1.6 kgfm
10 ~ 16 Nm
Clutch oil pipe flange nut
1.52 ~ 1.83 kgfm
15 ~ 18 Nm
Master cylinder bolt
3.05 ~ 4.07 kgfm
30 ~ 40 Nm
Fulcrum (clutch pedal bushing) bolt/nut
1.63 ~ 2.24 kgf m
16 ~ 22 Nm
Clutch pedal bracket mounting bolt
0.81 ~ 1.83 kgfm
8 ~ 18 Nm
Stopper bolt
1.63 ~ 2.24 kgfm
16 ~ 22 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
11
3. AIR BLEEDING
[Notice]
Keep the fluid level over MAX in reservoir during bleeding
operation.
Do not let the fluid contact a painted surface.
Specified oil
DOT 4
Capacity
Between Max and ADD
Procedure
1. Remove the air bleed bolt cap on the release cylinder.
[Notice]
2. Put the other side of the tube into a empty container.

3. Slowly pump the clutch pedal several times.
4. With clutch pedal fully depressed, open the air bleed
bolt and bleed the air and fluid from the fluid line.
5. Repeat step 3 through 4 until no more air bubbles are
in the escaping fluid.
CLUTCH ASSEMBLY
STAVIC - 2004.09
This work has to be done by two service persons.

After bleeding, check the clutch system for operation
and noise.
Use only Ssangyong genuine clutch fluid, and check
the clutch fluid level in reservoir.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4C
MAINTENANCE
Clutch Assembly
Preceding Work: Remove the transmission assembly.
1. Insert the centering pin (special tool) into center spline. Loosen the clutch cover bolts 1/2 turns in cross sequence
until the spring tension is released.
Tightening torque
2.4 0.3 kgfxm
[Notice]
1) Do not remove the bolts at a time, or clutch cover may be damaged or deformed.
2) If the clutch disk is to be reused, insert a mounting plate between the dia phram spring and cover plate when uninstall.
2. Unscrew the bolts and remove the clutch cover, pressure

plate and clutch disc.
[Notice]
1) Be careful not to drop the pressure plate and clutch disc.
2) Replace the clutch cover and disk at every disassembly.
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
21 ~ 27 Nxm
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
13
Concentric Slave Cylinder

Preceding Work: Remove the transmission assembly.
1. Unscrew the oil pipe nut(1), adaptor mounting bolt(3) and oil pipe nut(2) which connected to concentric slave(A)
from the inside of clutch housing.
2. Remove the oil pipe from the clutch housing.
3. Unscrew the concentric slave cylinder mounting bolts (3EA) and remove the concentric slave cylinder
assembly in the clutch housing.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4C
Clutch Master Cylinder

1. Drain the clutch fluid.
2. Pull out the snap pin and clevis pin from the clutch pedal
connection.
3. Remove the clutch tube.
Installation Notice
Tightening torque
15 ~ 18 Nm
[Notice]
Be careful not to contact the fluid into a painted surface.
4. Remove the master cylinder mounting nuts and pull off

the master cylinder.
Installation Notice
Tightening torque
8 ~ 18 Nm

6. Check the clutch pedal operation.
7. Perform the air bleeding job.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
15
Clutch Fluid Pipe

1. Draw out the fluid.
2. Unscrew the bolt and remove the supply pipe from clutch
master cylinder.
3. Unscrew the supply pipe bolt and remove primary oil pipe
from clutch fluid chamber.
4. Unscrew the bolt and remove the secondary clutch fluid

pipe from clutch release chamber.
5. Install the pipes. Be careful not to mix the pipes.
[Notice]
Make sure to bleed the air from the system after
installation.
Check each pipe bolt for oil leaks.
Clutch pipes are reusable. However, must check the pipes
for damages and cracks.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4C
Clutch Pedal
1. Remove the snap pin from master cylinder push rod and
remove the clevis pin from pedal.
2. Remove the turnover spring.
3. Unscrew the fulcrum bolt and remove the clutch pedal

from bracket
4. Unscrew the bolts and remove the master cylinder.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
17
5. Unscrew the mounting bolts and remove the clutch pedal

bracket.
Installation notice
1. Install in the reverse order of removal. Adjust pedal stroke
after installation.
[Notice]
Description
Tightening Torque
Fulcrum bolt/nut
16 ~ 22 Nm
Bracket mounting bolt
8 ~ 18 Nm
Stopper bolt
16 ~ 22 Nm
1. Apply long-life grease (T/M DBL 6611.00) to the connections.

2. Remove foreign materials.
3. Keep the tightening torque.
4. Replace the bushings with new ones.
Inspection and adjustment

1. Pedal Stroke (A)
Maximum pedal stroke
158 mm
2. Pedal Height (B)

Height (from carpet)
192 5 mm
[Notice]
To adjust the pedal stroke, loosen the lock nut (C) of the
stopper bolt (D) and turn the stopper bolt until the stroke is
correct. After adjustment, tighten the lock nut.
3. Pedal Free Play (E).

Free play
5 ~ 10 mm
[Notice]
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is
correct.
4. Check the fulcrum bolt and the bushing for wear, the
pedal for bending and the spring for damage.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4C
2. INSPECTION
Check any heat damage, abnormal noise, poor rotation
and wear of the concentric slave cylinder bearing.
Clutch Cover Assembly

Check the diaphragm spring tip for wear and height
unevenness.
Unevenness limit
0.8 mm
Check the pressure plate surface for wear, crack and

discoloration.
Check the strap plate rivet for looseness and replace if
necessary.
Clutch Disc
Check the facing for rivet looseness, sticks, oil and grease.
Measure the rivet head depth. If out of limit, replace the
disc.
Wear limit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
0.3 mm
CLUTCH ASSEMBLY
STAVIC - 2004.09
18
4C
2. INSPECTION
Check any heat damage, abnormal noise, poor rotation
and wear of the concentric slave cylinder bearing.
Clutch Cover Assembly

Check the diaphragm spring tip for wear and height
unevenness.
Unevenness limit
0.8 mm
Check the pressure plate surface for wear, crack and

discoloration.
Check the strap plate rivet for looseness and replace if
necessary.
Clutch Disc
Check the facing for rivet looseness, sticks, oil and grease.
Measure the rivet head depth. If out of limit, replace the
disc.
Wear limit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
0.3 mm
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
19
Clutch Disc Run-Out

Measure the clutch disc run-out and replace if necessary.
Run-out limit
0.7 mm
Pressure Plate
1) Check the pressure spring for wear.
[Notice]
The excessively worn components should be replaced.
2) Check the alignment conditions of clutch housing as

follows:
Install the magnetic holder on pressure spring.
Alignment check for housing bore
A. Install a dial gauge in the housing bore.
B. Measure and record the pointer value while
rotating the crankshaft.
Alignment check for clutch housing surface

A. Install a dial gauge on the clutch housing surface.
B. Measure and record the pointer value while
rotating the crankshaft.
[Notice]
If the pointer indicates beyond 0.010 inch, align the clutch
housing by inserting shims between the housing and clutch.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4C
3. SPECIAL TOOLS AND EQUIPMENT

661 589 00 15 00 (L 99 30 001 0B)
Application
Centering the clutch disc
Centering pin
601 589 02 40 00 (A 99 10 014 0B)
Locking the crankshaft
Engine lock
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
CLUTCH ASSEMBLY
STAVIC - 2004.09
4C
21
TROUBLE DIAGNOSIS
1. DIAGNOSTIC INFORMATION AND PROCEDURES
Check
Action
Excessive wear of facing
Replace
Hard or oily facing
Repair or replace
Damaged pressure plate or flywheel
Replace
Damaged or burnt diaphragm spring
Replace
Clutch pedal free play insufficient
Adjust
Faulty operation of clutch pedal
Repair or replace
Worn or damaged clutch disc
Replace
Vibration or excessive run-out of disc
Replace
Rust or wear of disc spline
Repair or replace
Oily facing
Repair or replace
Damaged diaphragm spring
Replace
Excessive clutch pedal free play
Adjust
Excessive clutch pedal free play
Adjust pedal freeplay
Faulty clutch release cylinder
Repair release cylinder
Worn disc, excessive run-out, damaged lining
Repair or replace
Dirty or burred splines on input shaft or clutch disc
Repair as necessary
Damaged clutch pressure plate
Replace
Oily facing
Repair or replace
Hard or faulty facing
Replace
Burnt torsion spring
Replace
Faulty pressure plate
Replace
Bent clutch diaphragm spring
Replace
Hard or bent flywheel
Repair or replace
Engine mounts loose or burnt lever
Tighten or replace
Poor lubrication on clutch cable
Lubricate or replace
Poor lubrication on pedal shaft
Lubricate or replace
Poor lubrication on clutch pedal
Repair
Insufficient clutch pedal free play
Adjust
Excessive wear of facing
Replace
After disengagement
Worn or damaged release bearing
Replace
When disengaging
Poor lubrication contact surface of bearing
Replace
Faulty installation of clutch assembly or bearing
Repair
Damaged pilot bushing
Replace
Clutch slips
Poor disengagement
Hard to shift or will not shift
Clutch chatters when starting
Difficult pedal operation
Not using the clutch

Clutch noisy
Possible Cause
Clutch pedal is partially

depressed and vehicle
speed is reduced
[Notice]
Clutch cover and disk should be replaced altogether.
CLUTCH ASSEMBLY
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
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4D
GENERAL INFORMATION
1. LAYOUT
Sub frame
T/M
Front propeller shaft
Exaust pipe
Transfer case (TOD)
Rear propeller shaft
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4D
2. GENERAL DESCRIPTION
TOD system means the full time 4WD system and the
registered trade mark of Borg Warner. TOD is an abbreviation of Torque On Demand.
Distribution of Driving Force

According to Road Surface
TOD (Torque On Demand) system, which is superior than

existing Full Time 4WD, checks the road surface and vehicle conditions via various sensors and, subsequently,
according to the situations and conditions, distributes the
most optimal driving force to front wheels and rear wheels
by activating the electro-magnetic clutch located inside of
TOD Transfer Case.
1. On normal road surface
TOD receives the speed signals from speed sensors installed in front axle and rear axle, the TPS signals from
engine, and the operating signals from ABS control unit
via CAN. Based on these data, TOD control unit controls
the electro-magnetic clutch to distribute the 3:97 ~ 44:56
of driving force to front wheels and rear wheels.
2. On paved road with high speed
The conventional system uses FR driving (theoretically,

the 100 % of driving force is transferred to rear wheels) on
normal paved road. When the system detects a slip in the
rear wheels, a proper percentage of driving force is transferred to front wheels.
TOD control unit receives the wheel speed signals from
the speed sensors in propeller shaft of transfer case and
engine output information from the engine control unit. TOD
control unit changes the pressure force of the electromagnetic clutch based on the analyzed data.
In vehicle with existing part time transfer case, when

a driver turns the steering wheel to park in the 4WD
mode, the vehicle may halt sensation of tight corner
braking phenomena. However, in vehicle with TOD
system, this phenomena does not occur and the
driving force is properly and automatically distributed.
Driving at high speed on roads such as highway
mainly uses rear wheels as driving wheel. At this
moment, some of torques is also distributed to front
wheels so that the vehicle could maintain safe ground
grab capacity against side winds and rain. Distribution
ratio: 15 % for front wheels and 85% for rear wheels.
3. When turning on the road with low friction rate
During cornering on roads such as unpaved, snowy,
icy and muddy, ground grab capacity is increased
by distributing required torque and, at the same time,
comfortable steering operation is maintained by
controlling the ground grab capacity at high level.
Distribution ratio: 30 % for front wheels and 70 % for
rear wheels.
4. When climbing or starting off on the road with low
friction rate
In order to secure the maximum ground grab capacity
and driving force during climbing or starting off on the
roads such as unpaved, snowy and icy road, the
system controls the driving force to distribute properly
in full 4WD mode. Distribution ratio: 44 % for front
wheels and 56 % for rear wheels.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
Transfer Case
Planetary gear set
Planetary Gear set consists of sun gear, ring gear and carrier. It is engaged with the gear in HIGH-LOW collar to
increase the driving force by reducing vehicle speed.
Sun gear is connected to input shaft and ring gear is fixed into the transfer case.
Splined rear output shaft is able to slide on the HIGH - LOW collar.
The inside and outside ends of HIGH - LOW collar have machined gear. The input shaft transmits the power to driving
wheels by engaging with sun gear and carrier gear.
If the 4WD switch is at 4WD HIGH, the TOD control unit operates the shift motor to engage HIGH - LOW collar
directly with input shaft for transmitting the driving force to front and rear propeller shafts.
When a driver selects 4WD LOW, the TOD control unit controls the electro-magnetic clutch and operates the shift
motor to engage HIGH - LOW collar with carrier. The power from transmission is increased up to 2.48:1 by reduction
ratio from planetary gear, and then is sent to front and rear propeller shafts.
Ball type slant cam and clutch disc pack

If the speed sensors installed on front and rear propeller shafts
detect the slips at front and rear wheels, and these slips exceed the specified range, TOD control unit controls electromagnetic clutch to transmit driving force to front wheels. At
this time, ball slant cam is moved to compress multi-disc
located in clutch disc to transmit driving force to front wheels.
TOD
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4D
Electro Magnetic Clutch (EMC)

EMC consists of coil and housing. TOD control unit controls EMC by controlling duty cycle according to the road and
driving conditions. These controls use the continuity time and amount of electric current to determine the torque to be
transmitted to front wheels.
Measuring the rotating speed

of front propeller shaft
Measuring the rotating

speed of rear propeller shaft
Is the wheel slip exceeded

allowable limits?
NO
YES
Decreases clutch engagement
Increases clutch engagement
Basic controls in EMC
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
TOD
STAVIC - 2004.09
4D
Signal Flow
Instrument Panel
4WD Switch
TOD Control
Output
Unit
Input
Rear Speed
Manetic Clutch
Motor
Front Output
TOD
STAVIC - 2004.09
Front Speed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4D
Power Flow
4H Mode (4WD Drive - High Speed)
Rear Axle
(Rear Wheel)
Transmission
Front Axle
(Front Wheel)
Front Speed
Sensor
Rear Speed
Sensor
Throttle Open
Rate
(TPS Value)
TOD Control Unit
Transmission
Input Shaft
Magnetic Clutch
Output Shaft
Force Distribution Unit

BALL RAMP
Driving Sprocket
Multi-Plate Clutch
Chain
Front Propeller
Shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear Propeller
Shaft
TOD
STAVIC - 2004.09
4D
4H Mode (4WD Drive - Low Speed)
Rear Axle
(Rear Wheel)
Transmission
Front Axle
(Front Wheel)
Front Speed
Sensor
Rear Speed
Sensor
Throttle Open
Rate
(TPS Value)
Transmission
Input Shaft
TOD Control Unit
Magnetic Clutch
MAX DUTY
Planetary Gear
(2.483)
Force Distribution Unit

BALL RAMP
Driving Sprocket
Multi-Plate Clutch
Output Shaft
Chain
Front Propeller
Shaft
TOD
STAVIC - 2004.09
Rear Propeller
Shaft
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4D
Specifications
Description
TOD
Specification
Model
TOD transfer case
Overall length
343.0 mm
Weight (including oil)
37.9 kg
Shifting mode
Gear ratio
Oil specification
4H and 4L
High
1:1
Low
2.48:1
Specification
Capacity
Change interval
TOD
control
unit
CHANGED BY
EFFECTIVE DATE
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1.4
Check at every 15,000 km,
replace at every 60,000 km
Approx. 76 kgm
Maximum torque (front)

Voltage
Ssangyong genuine oil

(ATF S-3, S-4 or Dexron II/III)
Normal operating
range
9 ~ 16 V
CAN communication
6 ~ 16 V
Current (below maximum

operating voltage)
IG switch OFF
2 mA
IG switch ON
1A
Maximum operating
current
Motor OFF
7A
Motor ON
20 A
TOD
STAVIC - 2004.09
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11
3. CIRCUIT DIAGRAM
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STAVIC - 2004.09
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4D
4. OPERATION
System Layout
Combi meter
4WD switch
TOD control unit
Output
Input
Rear speed
Magnetic clutch
Motor
Front output shaft
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Front speed
TOD
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13
4WD Operation Overview

Application
Driving type
Mode Position
4H
4L
Transferring
4H 4L
Operation Condition
4WD Drive
(High Speed)
Normal Driving on the normal road or highway, or high speed driving.
4WD Drive
(Low Speed)
Max driving force requiring condition such as towing, rough road.
4WD Drive
High Speed
Low Speed
A vehicle should stop for transfer.
Slipped road such as snow, rainy, sand, mud etc.
Same function as part time transfer case 4L.
Manual Transmission
Transfer starts after the vehicle stops and the clutch is applied
Automatic Transmission
Transfer starts after the vehicle stops and the shift lever is shifted
[N] position.
[Notice]
To make the mode shift easier, stop the vehicle, depress the brake pedal, select the mode switch, and move the selector
lever with the sequence of [N-P-N].
Mode Switch
Selection Mode
The TOD system has 2 selectable mode, 4H and 4L.
4H is the normal operating mode when drive of which
gear ratio is 1:1 and 4L mode distributes power to front
and rear wheels 50:50 of which gear ratio is 2.48:1.
4L Mode
When selecting 4L mode, EMC is locked to apply maximum
torque into front and rear propeller shafts (when the wheel
speed is more than 87Hz). Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes
from 1:1 to 2.48:1 by planetary gear set.
Releasing the 4L Mode

When selecting 4H mode, 4L drive mode is released and 4H
mode is resumed.
4H switch: Self-return type
4L switch: Push lock type
TOD
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4D
COMPONENTS
1. TOD ASSEMBLY
Front case
Rear cover
T/M
RR. Propeller shaft
Frt. Propeller shaft
Front & rear
Shift motor/Electronic
speed sensor
magnetic clutch
Input shaft
Rear cover
Companion flange
Air bleeder cap
Shift motor
Rear speed sensor

Front companion flange
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TOD
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15
2. TCCU (TRANSFERCASE CONTROL UNIT)
Location Under Drivers Seat
Item
TCCU
CAN
Cluster lamp
CAN
Clutch signal (M/T)
CAN
Neutral signal (A/T)
CAN
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4D
TCCU
Description
New TCCU
Connector type
Two separated connectors
Number of pins
30
Weight
0.22 kg
CAN-BUS
CAN communication
Lamp
CAN communication
Clutch signal (M/T)
CAN communication
Neutral signal (A/T)
CAN communication
Appearance and Function

Pin No.
Description
Pin No.
Description
Motor HI - LO
16
Speed sensor voltage supply
Motor LO - HI
17
Ground
EMC
18
Ground
Battery
19
Battery
Ignition
20
K-Line
Position ground
21
N/A
N/A
22
CAN H
N/A
23
CAN L
4H-4L switch
24
N/A
10
Position 2
25
ABS operation
11
Front speed sensor
26
N/A
12
N/A
27
Position 1
13
Ground speed sensor
28
Position 3
14
Motor HI-LO
29
Rear speed sensor
15
Motor LO-HI
30
Position 4
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17
Transfer Case Block Diagram
Battery voltage
19
15
Shift motor output

(Motor LO-HI)
T
Ignition switch ON/
OFF
14
Shift motor output

(Motor HI-LO)
EMC
Position encoder
ground
(Return position)
13
Speed sensor ground

(Return position)
16
Front/rear speed
Sensor 5V power
supply
20
Self diagnosis
D
Position 1
27
Position 2
10
Position 3
28
Position 4
30
C
O
N
4H/4L switch signal
T
R
O
Front speed
sensor signal
11
Rear speed
sensor signal
29
U
N
CAN HIGH
22
I
T
CAN LOW
23
17
18
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4D
Section
Pin No.
Name
Description
Power
supply
17, 18
Ground
TOD control unit ground
4, 19
B+
TOD control unit battery voltage input
Input side
Ignition switch
Ignition switch power

: ON - over 4 V, OFF - below 0.9 V
27
Position 1
Position encoder shift motor position recognition

HIGH - over 4 V, LOW - below 0. 9 V
10
Position 2
Same as above
28
Position 3
Same as above
30
Position 4
Same as above
4H and 4L switch
Mode input according to 4H and 4L selection

: HIGH - over 4 V, LOW - below 0.9 V
11
Front speed sensor
Front speed sensor (hall effect) signal input
29
Rear speed sensor
Rear speed sensor (hall effect) signal input
25
ABS operation
ABS operating signal input (ABS ON/OFF)

Operation - over 4 V, Not operation - below 0.9 V
(NON CAN ABS model)
Both sides
Output side
22
CAN HIGH
CAN bus HIGH line
23
CAN LOW
CAN bus LOW line
20
K - LINE
Connected to trouble diagnosis connector
16
Speed sensor voltage
Supplying 5V to front/rear speed sensors
1, 14
Motor HI-LO
Motor output port

- Connected to battery when shifting to LO from HI
- Connected to ground when shifting to HI from LO or
braking the motor
2, 15
Motor LO-HI
Motor output port

- Connected to battery when shifting to HI from LO
- Connected to ground when shifting to LO from HI or
braking the motor
EMC
Supplying the voltage to clutch coil

- Frequency: 50 Hz, - Duty ratio: 6 ~ 88 %
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Speed return
Providing the ground to position encoder
13
Speed return
Providing the ground to speed sensor
TOD
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19
SYSTEM OPERATION
TCCU Initialization
TCCU sends relevant data to meter cluster via CAN to diagnose and check the indicators when the ignition switch is
turned to ON. At this time, the 4WD indicators (4WD LOW, 4WD HIGH, 4WD CHECK) comes on for 0.6 seconds.
If the selector switch position and the shift motor position code does not match when the IG power is turned ON, the
shift is controlled to move in the direction of the selector switch position
Interpretation of Position Sensor

- When the 4H/4L switch is operated and the position sensor recognizes the shift motor position while the system is
energized, the system operates as follows:
4H/4L Switch Input
Motor Position
Operation
4H
Left stop
Does not operate, 4L lamp off
4H
Left top
4H
Top
4H
Right top
- 4L lamp flickers
- Tries shifting to 4H if shifting conditions are satisfied.
- After shifting to 4H the flickering of 4L lamp stops.
4H
Zone 1
Same as above
4H
Neutral
Same as above
4H
Zone 2
Same as above
4H
Bottom
Same as above
4H
Right stop
Same as above
4L
Left stop
- 4L lamp flicker
- Tries shifting to 4L if shifting conditions are satisfied.
- After shifting to 4L the 4L lamp lights on.
TOD
STAVIC - 2004.09
4L
Left top
Same as above
4L
Top
Same as above
4L
Right top
Same as above
4L
Zone 1
Same as above
4L
Neutral
Same as above
4L
Zone 2
Same as above
4L
Bottom
Does not operate, 4L lamp lights on
4L
Right stop
Does not operate, 4L lamp lights on
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4D
If 4H/4L switch position is not matched with shift motor position code with the ignition switch ON, the shift requirements operate to the direction of 4H/4L switch. However, the shifting requirements should be met to shift.
Shifting requirements:
- The transmission is in neutral for 2 seconds after the shift is requested.
- Both propeller shaft speeds are below 43 Hz.
A command to shift will only be acted upon if the TOD is reading a valid code at the time the command to shift is made.
After a shift has started, the TOD will power the shift motor until the code for the requested position is read. If an invalid
code is read, the TOD will go into a default mode.
During a shift attempt, the shift motor will be energized for a maximum of 5 seconds.
In case of manual transmission, the clutch pedal should be depressed.
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21
ELECTRIC SHIFT SYSTEM OPERATION

The electric shift system is responsible for changing the transfer case gear ratio by controlling the electric shift motor.
The TOD monitors the 4H/4L switch, neutral switch, speed sensors, position encoder, and ignition switch.
A range change is initiated when:
1. The 4H/4L switch is changed from 4H to 4L or from 4L to 4H.
2. The motor position (as indicated by the position encoder) does not match the 4H/4L switch immediately after the
ignition is turned on.
Shift Requirements
When a range change is initiated a diagnostic test will be completed on the motor, speed sensors, and position
encoder. If the diagnostic test fails, the shift will not be attempted. If all components are operating properly, the TOD will
attempt a range change after the following shift requirements are met:
1. The transmission is in neutral for 2 seconds after the shift is requested.
In case of manual transmission, the clutch pedal should be depressed.
2. Both propeller shaft speeds are below 43 Hz.
If the transmission is taken out of neutral before 2 seconds has elapsed, or either propeller shaft speed increases above
the limit, the shift will be suspended and the 4L indicator will continue to flicker until the requirements are met again or
the 4H/4L switch is returned to the original position. However, if the initial switch position is 4L, 4L indicator remains
on. If the shift requirements are met, the shift motor attempt to shift again.
Range Change
When the shift requirements are met, the motor rotates to the appropriate direction (as determined by the selector
switch) until one of the following occurs:
1. The motor reaches its destination.
2. The motor is on for 5 seconds without reaching its destination. The shift has failed and the TOD will respond as
default mode.
3. A fault occurs with either the motor or position encoder. Refer to the diagnosis requirement.
When the motor is energized, the Ignition, 4H/4L switch, propeller shaft speeds, and transmission neutral inputs are
ignored.
Shift operation is only allowed when some conditions are satisfied. These shift conditions should be satisfied for 2
seconds before starting motor. The motor has three seconds of delay at its initial operation to do trouble diagnosis.
Once the motor starts, the shift conditions are no longer checked.
Shift conditions are as follows:
-
Normal battery voltage and shift motor for all gears

Shift operation between 2H/4H and 4L is only available when the vehicle speed is below 43 Hz.
No defective speed sensor
The selector lever should be in N position (in case of manual transmission, the clutch pedal should be depressed).
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4D
Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:
- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Motor Controls
The shift steps have the sequence of 4H 4L and 4L 4H 2H. TCCU operates the shift motor until it reads
required position code. If it detects the faulty code, the system is operated with the compensation mode.
Once the shift operation is started, it is completed regardless of ignition power. If there are not operating signals from
position sensor, the shifting failure due to timeout occurs. This failure appears when the shifting time between 2H
and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift. Once the shifting time exceeds
the specified time, TCCU cannot properly supply the voltage to shift motor and is operated in compensation mode.
Even though the system recognize a fault before motor starts, it is considered as fault.
Motor stops operation when it reaches at target range.
Compensation Mode
The motor stops when the encoder related troubles are detected during shift operation. It moves toward LOW-HIGH
direction for 5 seconds so that the motor is not left in unidentified position.
Indicator Function on Shifting

Once a range change has been initiated the 4L Indicator will
begin to blink at a rate of 0.3 seconds on, 0.3 seconds off until
the shift is completed or canceled.
0.3 seconds
Shift completed
4L Indicator illuminates as below figure.
Electric Shift Default Mode

If the motor fails to reach its destination, the TOD will attempt
the following (in order):
1. The TOD will wait 3 seconds then attempt the shift again.
2. If the second attempt to reach the destination fails the
TOD will wait 3 seconds then attempt to rotate the motor
back to the original position. If successful, all future shifts
will be inhibited until the Ignition is cycled.
3. If the attempt to return to the original position fails, the
TOD will wait 3 seconds then attempt to rotate the motor
to the original position again. If the second attempt to
return to the original position is successful, the 4WD
CHECK indicator will be illuminated, and all future shifts
will be inhibited until the Ignition is cycled.
4. If the second attempt to return to the original position
fails the motor will be turned off, the 4WD CHECK
indicator will be illuminated, and all future shifts will be
inhibited until the Ignition is cycled.
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0.3 seconds
(4H 4L)
0.3 seconds
Shift completed
0.3 seconds
(4L 4H)
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STAVIC - 2004.09
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23
Etc
The TOD system is responsible for distributing torque between the front and rear axles. The TOD monitors the propeller
shaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to the front
axle by Pulse Width Modulating the current applied to the EMC.
Touch-off torque
The minimum EMC Duty Cycle is based on the vehicle speed and throttle position.
The TOD receives the TPS signal from the following sources:
On vehicles equipped with CAN, the TOD receives the TPS signal from the CAN bus.
When slip detection

The TOD continuously monitors the front and rear propeller shaft speeds to detect wheel slip.
Wheel slip control
When wheel slip is detected the TOD controls the EMC duty cycle as necessary until the wheel slip is reduced below
the allowable limit. The EMC Duty Cycle will then be reduced to the Touch-Off value.
Brake/ABS strategy
When the ABS System is active, the EMC Duty Cycle is set to a fixed duty cycle (30 %) to aid in braking without
counteracting the ABS System.
4L strategy
When the system is operating in 4L, the TOD continues TOD (operation provided that the propeller shaft speed is below
87 Hz). When the speed increases above 10 Hz, the EMC Duty Cycle is set to the maximum value (88 %) which applies
the maximum available torque to the front axle.
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4D
Shifting Sequence
Flow chart
Start
Shift
requirements
No
Yes
Satisfied shift
conditions for 2
seconds
Check shift
conditions
Yes
Analyzing position
encoder
No
Is the position
code valid?
Canceling general encoder

DTC Shift is not available
during ignition cycle
No
Yes
Move further to
requested direction
Does the motor

operate for
maximum limit?
Yes
Motor stops Shift

time out DTC
No
Is the position
code valid and
sequential?
No
Moto stops
General
encoder DTC
Yes
No
Reached at
target location?
Motor ON to L-H
during maximum limit
Shift is not available

during ignition cycle
Yes
Shift motor OFF
Completed
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STAVIC - 2004.09
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25
Shift Requirements
If 4H/4L switch position is not matched with shift motor position code with the ignition switch ON, the shift requirements
operate to the direction of 4H/4L conversion switch.
The next shift requirements are identified only when those are different from current operation.
Shift Conditions
Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must
satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose
the system.
The shift requirements are as follows:
- There should be no fault with battery voltage and shift motor for all shifts.
- Shift between 4H and 4L is operated only under the vehicle speed of below 43 Hz.
- There should be no fault with speed sensors.
- Transmission must be in neutral position (In case of manual transmission, the clutch pedal should be depressed).
Reading position encoder

The position encoder is the code that TCCU can determine the shift motor position.
Position
Motor Position
Left Stop
Left top
Top
Right top
Zone 1
Neutral
Zone 2
Bottom
Right stop
Off State
TOD
STAVIC - 2004.09
Remark
Input voltage
1 : above 4.5V (HIGH)
0 : below 0.5V (LOW)
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4D
3. SPEED SENSOR AND CLUTCH COIL

The front and rear speed sensor utilizes the hall effect. These sensors generate 0V and 5V of square type digital
wave according to the rotation of the wheel with teeth of transfer case front and rear output shaft. The speed
signal from front and rear propeller shaft is entered into TOD control unit.
Pin
Function
Clutch coil
6, 7
Sensor power supply (5V)
1, 2, 5
Sensor signal
Sensor ground
1(G)
2(G)
3(B)
5(Sb)
6(Gr/R)
7(Gr/R)
4(Br)
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STAVIC - 2004.09
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27
4. SHIFT MOTOR CONNECTOR

When selecting a position in 4WD switch (4H/4L), TOD control unit exactly changes the motor position to 4H and 4L by
detecting the electric signals from position encoder that monitors motor position.
Pin
Function
Position A
Position B
Position C
Position D
Position ground
Control (4L - 4H)
Control (4H - 4H)
1(Br/W)
2(P/W)
3(W)
5(Y/W)
6(Y)
7(P)
4(V)
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4D

1. TCCU
1. Move the drivers seat to for front and open the seat cover.
2. Unscrew TCCU mounting nuts (M5-2EA)
3. Disconnect the TCCU connector and seperate the unit.

[Notice]
Be careful not to apply any impact to TCCU body.
Installation Notice
Tightening torque
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10 1.0 Nm
TOD
STAVIC - 2004.09
4D
29
2. SHIFT MOTOR
2. Disconnect the shift motor/electronic magnetic clutch connector (black, 7-pin) and front and rear speed sensor
connector (white, 4-pin) at the rear top section of the transfer case.
3. Disconnect the front and rear speed sensor connector (white, 7-pin) from bracket.
4. Remove shift motor mounting bolts.

5. Remove bracket mounting bolt.
[Notice]
Remove two bolts for fixing the motor and bracket before
removing the shift motor and bracket.
TOD
STAVIC - 2004.09
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4D
6. Pull the shift motor assembly out while keeping the level.
7. Clean the mating surface of the transfer case and shift

motor.
[Notice]
Do not disassemble the shift motor since it is replaced as an
assembled unit.
8. Apply sealant on the mating surface if new shift motor

assembly.
9. Install in the reverse order of removal. Make sure that
the mode switch selection is matched with the motors
driving position before installation.
[Notice]
To do that, install a new shift motor on the same location
that the used shift motor was on.
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STAVIC - 2004.09
4D
31
3. SPEED SENSOR
Rear speed sensor
Front speed sensor
Rear speed sensor connector
1.
2.
3.
4.
5.
Disconnect the negative battery cable.

Remove the shift motor assembly.
Disconnect the front and rear speed sensor connector (white, 7-pin) at the rear top section of the transfer case.
Disconnect the speed sensor connector from the locking sleeve.
Remove the wire fixing retainer at the rear side of disconnected connector.
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4D
6. Remove the rear speed sensor bolts on the rear case flange.
Tightening torque
3 ~ 6 Nm
7. Remove the rear speed sensor with a suitable tool.

[Notice]
Do not apply excessive force to protect mounting area and sensor.
8. Remove the tapings in both sides of protective tube.

9. Remove the tube.
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STAVIC - 2004.09
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33
10. Hold the L pin in speed sensor connector with long nose pliers and push it rearward to disconnect from the
connector.
11. Disconnect the M and N pin and wire from the

connector with same manner.
[Notice]
EMC wire cannot be disconnected from outside, therefore do
not try to disconnect it.
12. Get a new speed sensor.

13. Insert three pins and wires into each location from rear
side of the connector.
14. Hold each pin with long nose pliers and pull it to securely
install in the connector.
15. Insert each rubber cap into the connector to prevent the
pins from disconnecting.
16. Insert the protective tube for connector into the harness.
17. Bind both ends of the protective tube with tape.
18. Install the rear speed sensor into the mounting hall and
press both ends of it to be securely seated.
19. Tighten the bolts.
Installation Notice
Tightening torque
3 ~ 6 Nm
20. Install the speed sensor connector. Insert the connector

into the locking sleeve.
[Notice]
Remove the shift motor first before removing the front
propeller shaft speed sensor. When replacing the sensor
assembly after removing the shift motor, use the same manner
for removal of rear speed sensor.
TOD
STAVIC - 2004.09
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4D
4. TOD ASSEMBLY
2. Lift up the vehicle and fix it safely.
3. Place the empty container to collect the draining oil.
4. Remove the drain plug and drain the oil. Reinstall the
drain plug.
[Notice]
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector from

rear side of transfer case.
[Notice]
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect the shift motor/clutch coil connector (black,

7-pin) and front and rear speed sensor connector (white,
7-pin) at the rear top section of the transfer case.
7. Remove the breather hose.

8. Support the transfer case with jack and remove the front
propeller shafts bolts (4ea).
Installation Notice
Tightening torque
81 ~ 89 Nm
9. Remove the rear propeller shaft mounting bolts (4).
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STAVIC - 2004.09
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35
10. Unscrew the bolts and remove the crossmember from

the transmission.
L/R Mounting Bolt
21 ~ 35 Nm
Center Mounting Bolt
62 ~ 93 Nm
11. Remove the insulator mounting bolts.

Installation Notice
Tightening torque
62 ~ 93 Nm
12. Unscrew the bolts and remove the transfer case.

Installation Notice
Tightening torque
20 ~ 25 Nm
[Notice]
Apply long-life grease to the inner spline of transfer case
input shaft.
TOD
STAVIC - 2004.09
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4D
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37
TOD ASSEMBLY
1. CROSSE SECTIONAL DIAGRAM
4H-4L planetary gear set
Chain
Clutch pack
EMC
Ball lamp
Input shaft
Oil pump
4H-4L shift motor

Front wheel
output shaft
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STAVIC - 2004.09
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4D
Exploded View
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STAVIC - 2004.09
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39
1. Snap ring
35. Breather
2. Snap ring
37. Output shaft
3. Snap ring
38. Dust shield
4. Bearing
39. Magnet
5. Hub
40. Snap ring
6. Input shaft assembly
41. Lower sprocket
7. Thrust plate
42. Tone wheel (lower)
8. Sun gear
43. Chain
9. Snap ring
44. Thrust bearing assembly
10. Carrier assembly
45. Retaining ring
11. Reduction hub
46. Bearing
12. Main shaft assembly
47. Bearing
13. Geroter pump assembly
48. Cover
14. Thrust washer
49. Clip
15. Hose clamp
50. Bolt
16. Hop
51. Oil seal
17. Filter
52. Washer
18. Electric coil assembly
53. Nut
19. Cam/coil housing assembly
54. Companion flange
20. Ball
55. Oil seal
21. Cam
56. Spacer
22. Spring
57. Tone wheel (upper)
23. Armature
58. Nut
24. Insulator washer
59. J clip
25. Retaining ring
60. Hexagon bolt
26. Clutch pack assembly
61. Clip
27*. Sprocket assembly
62. Connector
28. Shift rail
63. Connector lock
29. Shift fork assembly
64. Hexagon cap screw
30. Electric shift cam
65. Speed sensor (upper)
31. Torsion spring
66. Electric motor assembly
32. Shift shaft
67. Oil seal
33. Retaining ring
68. Pipe plug
34*. Transfer case assembly
TOD
STAVIC - 2004.09
69. Speed sensor (lower)
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4D
2. DISASSEMBLY PROCEDURE
1. Disconnect transfer case from vehicle
2. Using a 30 mm thin-wall socket, first remove the rear
output nut, output shaft yoke washer, oil seal then the
case flange.
3. Disconnect shift motor/clutch coil connector and speed
sensor connector from upper bracket of transfer case.
[Notice]
When disconnect connector, pull forwards grasping
connector housing.
4. Remove outer tube on speed sensor connector.

5. Remove wire supporting cape back side of speed sensor
connector.
6. Disconnect pin of clutch coil wire (yellow) from speed

sensor connector (7 pin) using long-nose plier.
03E-019
7. Remove shift motor.

[Notice]
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
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AFFECTED VIN
TOD
STAVIC - 2004.09
4D
41
8. Disconnect front and rear speed sensor as needed.

9. Remove the 17 bolts that retain the front case to the rear
case.
10. Make sure that the front case is facing downward so

that the rear cover is facing upwards.
11. Remove the rear front case from the rear case.
12. Remove all traces of gasket sealant from the mating
surfaces of the front case and rear case.
13. If the speedometer drive gear is to be replaced, first
remove the flange seal by prying and pulling the curvedup lip of the flange seal.
[Notice]
Be careful not to damage the bearing, bearing cage or case.
Remove and discard the flange seal.
14. Remove the speedometer drive gear and upper tone wheel.
15. If the rear output shaft bearing requires replacing, remove
the internal snap ring that retains the bearing in the bore.
16. From the outside of the case, drive out the bearing using
the driver.
17. Remove the three nuts and washers retaining the clutch
coil assembly to the rear case.
18. Pull the assembly, along with the O-ring and wire, from
the case.
TOD
STAVIC - 2004.09
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4D
19. Remove bearing assembly from output shaft.

20. Remove the clutch housing from the output shaft.
21. Remove the balls and apply cam and wave washer from
the output shaft.
22. Remove snap ring from output shaft.
23. Remove clutch pack assembly from output shaft.
24. Remove the chain, driven sprocket and drive sprocket as

an assembly.
25. Remove thrust washer from output shaft.
26. Remove the magnet from the slot in the front of the case
bottom.
27. Remove the output shaft and oil pump as an assembly.
28. If required, to remove the pump from the output shaft,
rotate the pump to align.
29. Pull out the shift rail.
30. Remove the helical cam from the front case.
31. If required, remove the helical cam, torsion spring and
sleeve from the shaft.
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STAVIC - 2004.09
4D
43
32. Remove the high-low range shift fork and collar as an

assembly.
33. Expand the tangs of the large snap ring in the case.
34. With the input shaft against a bench, push the case down
and slide the main drive gear bearing retainer off the
bearing.
35. Lift the input shaft and front planet from the case.
36. If required, remove the oil seal from the case by prying
and pulling on the curved-up lip of the oil seal.
[Notice]
37. Remove the internal snap ring from the planetary carrier.
38. Separate the front planet from the input shaft.
39. Remove the external snap ring from the input shaft.
40. Place the input shaft in a vise and remove the bearing.
41. Remove the thrust washer, thrust plate and the sun gear
off the input shaft.
42. Inspect the bushing and needle bearing in the end of the
input shaft for wear or damage.
[Notice]
Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing and needle bearing must be replaced as a set.
TOD
STAVIC - 2004.09
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AFFECTED VIN
44
4D
43. If replacement of the needle bearing and bushing is

required, press the bearing and bushing is required, press
the bearing and bushing out as follows:
Position the input shaft on Axle Bearing/Seal plate,
and using Pinion Bearing Cone Replacer as a spacer.
Insert Input Shaft Bearing Remover into the input shaft
so it is resting on top of the bearing cage.
Tighten the actuator pin until it stops, then press the
bearing and bushing out together.
44. If required, remove the front yoke to flange seal by prying

and pulling on the curved-up lip of the yoke to flange
seal.
[Notice]
45. If required, remove the internal snap ring retaining the

front output shaft ball bearing and remove the bearing.
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STAVIC - 2004.09
4D
45
3. ASSEMBLY PROCEDURE
1. Before assembly, lubricate all parts with Automatic
Transmission Fluid or equivalent.
2. If removed, drive the bearing into the front output case
bore.
[Notice]
Drive the bearing in straight, making sure it is not cocked in
the bore.
3. Install the internal snap ring that retains the bearing to

the front case.
4. If removed, install the front yoke to flange seal in the
front case bore.
5. If removed, install the yoke to flange seal into the mounting
adapter bore.
6. If the input shaft needle bearing and bushing were

removed, install a new bearing and bushing as detailed
in the following steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
Position the input shaft on Axle Bearing/Seal Plate
or equivalent, and Pinion Bearing Cone Replacer as
a spacer.
Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
Press in a new bushing.
TOD
STAVIC - 2004.09
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46
4D
7. The recessed face of the sun gear and the snap ring
groove on the bearing outer race should be toward the
rear of the transfer case.
8. The stepped face of the thrust washer should face toward
the bearing.
9. Slide the sun gear, thrust plate and thrust washer into
position on the input shaft.
10. Press the bearing over the input shaft.
11. Install the external snap ring to the input shaft.
12. Install the front planet to the sun gear and input shaft.
13. Install the internal snap ring to the planetary carrier.
14. Place the tangled snap ring in the case. Expand snap
ring with snap ring pliers and install planetary carrier
assembly. Check installation by holding the case and
carefully tapping the face of the input shaft against a
wooden block to make sure the snap ring is installed.
15. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
16. Install the high-low shift fork and high-low collar as an

assembly into the front planet.
17. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
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AFFECTED VIN
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STAVIC - 2004.09
4D
47
18. Inspect the outside surfaces and bore of the oil pump.
19. Install the output shaft and oil pump in the input shaft.
Make sure that the internal splines of the ouput shaft
engage the internal splines of the high-low shift collar.
Make sure that the oil pump retainer arm and oil filter leg
are in the groove and slot of the front case.
20. Install the magnet in the slot in the front case just above
the oil filter leg.
21. Install the front output shaft in the front case.
22. Install the thrust washer on the rear output shaft.
23. Install the chain, drive sprocket and driven sprocket as

an assembly over the output shaft.
[Notice]
The driven sprocket (on the front output shaft) must be
installed with the marking REAR facing toward the rear case,
if so marked.
Drive sprocket has a bushing pressed into it.
TOD
STAVIC - 2004.09
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48
4D
24. Install tone wheel onto the front output shaft. Make sure
the spline on the tone wheel engages the spline on the
front output shaft.
25. Install clutch pack assembly onto the rear output shaft.
Make sure the spline of the clutch pack engages to the
spline of the sprocket.
26. Install snap ring onto the rear output shaft. Start the snap
ring over the spline and use the wave spring to seat the
snap ring in the snap ring groove.
If the snap ring will not install, the thrust washer inside
the clutch pack may not be seated properly.
27. Install wave spring, insulator washer and armature. (Three
offset slots must align with housing to be installed)
[Notice]
Three slots on the thrust washer must be aligned with the
three tabs on the clutch pack housing.
28. Install apply cam onto the rear output shaft,

29. Install three balls into the apply cam.
30. Install cam and coil housing assembly onto rear output
shaft.
31. Install thrust bearing assembly onto output shaft.
32. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing
Replacer and Driver Handle.
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AFFECTED VIN
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STAVIC - 2004.09
4D
49
33. If removed, install the rear output bearing in the rear case
bore. Drive the bearing into the rear case bore with Output
Shaft Bearing Replacer and Driver Handle. Make sure
that the bearing is not cocked in the bore.
34. Install the internal snap ring that retains the bearing to
the rear case.
35. Install the clutch coil from inside the rear case until the
wire and studs extend through the cover.
[Notice]
Do not kink or trap the wire while seating the clutch coil to
the case.
36. Install the washers and nuts and tighten.

Installation Notice
Tightening torque
8 - 11 Nm
(71 - 97 lb-in)
37. Slide the spring spacer on the camshaft and position it

beneath the drive tang.
38. Place the torsion spring on the camshaft. Position the
first spring tang to the left of the camshaft drive tang.
39. Rotate the second spring tang clockwise past the drive
tang.
43a
TOD
STAVIC - 2004.09
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50
4D
40. Push the torsion spring and sleeve in as far as it will go.
41. Install the helical cam and slide the drive tang between
the torsion spring tangs as far as it will go.
42. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs
so that they are pointing toward the top side of the
transfer case and just touching the high-low shift fork.
[Notice]
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang end of
the motor shaft.
43. Install the shift rail through the high-low shift fork and
make sure that the reverse gear shift rail is seated in the
front case bore.
44. Install upper and lower speed sensors into the cover.
Feed the coil wire through the upper speed sensor wire
shield.
45. Install upper tone wheel, speedometer gear and rear

output seal. Use Output Shaft Seal Replacer and Driver
or equivalent to install seal.
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STAVIC - 2004.09
4D
51
46. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
47. The following procedure must be followed prior to installing
the rear case onto the front case half:
Align the output shaft with the rear case output shaft
bore.
Align the helical cam with the rear case motor bore.
If difficulty is encountered with seating the rear case,
tap the rear output shaft with a sharp blow using a
rubber mallet in a direction away from the triangular
shaft while pushing down on the rear case.
48. Install the bolts retaining the case halves and tighten.
Installation Notice
Tightening torque
25 - 37 Nm
(8 - 27 lb-in)
49. Install shift shaft oil seal if it is not installed.
50. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor.
[Notice]
If triangular shaft will not rotate, rotate the rear output shaft.
TOD
STAVIC - 2004.09
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4D
51. Tighten manually the two nuts that attach the slotted
support bracket to the end of the motor house.
52. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
53. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Installation Notice
Tightening torque
8 - 11 Nm
(71 - 97 lb-in)
54. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lock washer.
Installation Notice
Tightening torque
8 - 11 Nm
(71 - 97 lb-in)
55. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
Installation Notice
Tightening torque
3 - 6 Nm
(27 - 53 lb-in)
56. Install the clutch coil wire terminal(brown) and other shift
motor wires to the 7-pin connector(black).
57. Install the connector retainer at the connector end.
58. Connect the front and rear speed sensors wiring to the
7-pin connector(white).
59. Install the rear case flange on the output shaft.
60. Install the rubber seal, output shaft yoke washer and nut.
Tighten the nut.
Installation Notice
Tightening torque
137 - 196 Nm
61. Install the drain plug and tighten.

Tightening torque
19 - 30 Nm
(14 - 22 lb-in)
62. Fill the transfer case with 1.4 liters of Automatic

Transmission Fluid or equivalent.
63. Install the fill plug and tighten.
Installation Notice
Tightening torque
19 - 30 Nm
(14 - 22 lb-in)
64. Install the transfer case as outlined in removal and

Installation.
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TOD
STAVIC - 2004.09
4D
53

661 589 01 37 00 (W 99 31 001 1B)
Pliers
DW 220 - 080 (W 99 31 005 0B)

Oil seal installer
TOD
STAVIC - 2004.09
Application
Removal/installation of carrier
assembly in transfer case
Installation of oil seal to

transmission case
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4D
TROUBLE DIAGNOSIS
TCCU periodically monitors the input and output while the system is in operation. When a fault is detected, the trouble
code is stored into TCCU memory.
If the ignition switch is turned to OFF, TCCU stops monitoring for input and output, however, when the ignition switch
is turned to OFF before shifting completes, TCCU continues monitoring for input and output required for the shifting.
1. SELF DIAGNOSIS TEST

Shift Motor Test
When TOD control unit detects a fault in shift motor or position encoder for over 1 second, 4WD CHECK warning lamp
comes on and the trouble code is stored into memory.
Shift motor fault occurs when the motor is in OFF state:
- short to ground in motor HI-LO circuit
- short to ground in motor LO-HI circuit
- open in motor circuit
Shift motor fault occurs when the motor is in normal operation state:
-
short to ground in motor HI-LO circuit

short to ground in motor LO-HI circuit
short between motor LO-HI and motor HI-LO circuit
open in motor circuit
Position encoder fault occur when

- Detected unmatched code with 9 valid position codes
- An encoder circuit is short to ground
When the fault occurs before the shift operation is started, the TOD control unit does not respond to any shift
command.
When, after receiving shift command, the fault occurs without any operation, the TOD control unit cancels the
command and does not respond to any following shift command.
If TOD control unit, even while shift command is in progress, detects an invalid position code, it stops the operation
and turns motor to HIGH position. After then, TOD control unit does not respond to any shift command.
When the shift motor and position encoder assembly fault (fault other than motor fault that is caused when normal
power supply is applied) is restored continuously for 1 second, the TOD control unit function becomes normal. At
this time, 4WD CHECK warning lamp comes on but the trouble code is stored into memory.
The trouble code being detected in shift motor during its operation is defined as timeout.
The trouble code for shift motor can be erased by using scanner.
Position Encoder Test

When the system detects a fault in shift motor for over 1 second, 4WD CHECK warning lamp comes on and the
trouble code is stored into memory.
Position encoder fault can be divided into general encoder fault and short to ground of position encoder circuit.
- General encoder fault: Invalid position code input
- Short to ground of position encoder circuit: Ground for encoder circuit
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STAVIC - 2004.09
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55
Front Sensor Speed Test

When the system detects a fault from front speed sensor for over 0.5 second, 4WD CHECK warning lamp comes on.
At this time, the responds from TOD control unit are as follows:
If the system is in 4H state, the TOD control unit uses rear speed sensor value to determine the amount of EMC
touch off and the wheel slip control stops.
If the system is in 4L state, the EMC duty cycle is set at maximum value (according to the vehicle speed) until
system stops 4L operation.
All electrical shift operations are stopped until ignition switch is cycled from OFF to ON position. Any shift
operation in progress completes the process. When the front speed sensor is restored continuously for 0.5 seconds,
the TOD control unit becomes normal status. At this time, 4WD CHECK warning lamp comes on but the trouble
code still remains in the memory.
Rear Speed Sensor Test

When the system detects a fault from rear speed sensor for over 0.5 second, 4WD CHECK warning lamp comes on.
At this time, the responds from TOD control unit are as follows:
If the system is in 4H state, the TOD control unit uses front speed sensor value to determine the amount of EMC
touch off and the wheel slip control stops.
operation in progress completes the process. When the rear speed sensor is restored continuously for 0.5 seconds,
All Troubles from Speed Sensor

When the system detects a fault from front and rear speed sensors for 0.5 seconds, 4WD CHECK warning lamp
comes on. At this time, the responds from TOD control unit are as follows:
If the system is in 4H state, the TOD control unit is set up based on EMC touch off amount and the wheel slip
control stops.
operation in progress completes the process. When the rear speed sensor is restored continuously for 0.5 seconds,
EMC Test
The EMC tests whether the circuit is short or open to ground. When the system detects a fault for 0.8 seconds, 4WD
CHECK warning lamp comes on and TOD stops its operation. When the EMC is restored continuously for 0.8 seconds,
the TOD control unit functions normally. At this time, 4WD CHECK warning lamp comes on but the trouble code still
remains in the memory.
TOD
STAVIC - 2004.09
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4D
CAN TPS Test

When TCCU receives CAN message including TPS value of over 100 % continuously for 1 second, TCCU determines
it as signal error and 4WD CHECK warning lamp comes on.
When the system is in TOD mode, the TOD control unit considers that the throttle is in idle.
When the TPS value is restored continuously for 1 second, the TCCU functions normally and 4WD CHECK warning
lamp comes on but the trouble code still remains in the memory.
TCCU receives CAN TPS messages periodically. If TCCU cannot receive the messages for 4 periods, TCCU determines
it as signal loss. If it happens continuously for 1 second, TCCU considers it as the invalid signal and 4WD CHECK
warning lamp comes on.
When the CAN message including ABS value is restored continuously for 1 second, TCCU functions normally and
4WD CHECK warning lamp comes on but the trouble code still remains in the memory.
Transmission Neutral Test

If TCCU cannot receive the messages for 4 periods, TCCU determines it as signal loss. If it happens continuously for
1 second, TCCU considers it as the invalid signal and 4WD CHECK warning lamp comes on. And TCCU determines
that the transmission is not in neutral position.
When CAN message including indication of transmission in neutral is restored continuously for 1 second, TCCU
functions normally and 4WD CHECK warning lamp comes on but the trouble code still remains in the memory.
Stuck in Low Test

Stuck in low DTC is set when the shift conditions are satisfied, no encoder trouble exists and the TCCU is not
formed outside of shift range. Stuck in low trouble completing time is 1 second longer than the maximum shift. If the
trouble is detected, 4WD CHECK warning lamp comes on and shifting is not possible.
If stuck in low fault is not valid, it is erased at the next ignition cycle and the 4WD CHECK lamp lights out but fault
code remains in the memory.
CAN Bus Off Test

CAN bus off trouble is set when the transferring trouble exceeds 255 times and CAN bus in TCCU goes to off
condition. When the trouble counter exceeds 255 times, the signal is recognized as invalid and the 4WD CHECK
warning lamp comes on.
If CAN bus in TCCU goes to reset condition while in Bus off condition, the transferring and receiving signals are
interrupted and the synchronization for bus disappears. Once it is reset, TCCU tries to resynchronize with CAN bus.
When the resynchronization stops, the communication is resumed. At this time, the trouble is erased and 4WD
CHECK warning lamp comes on but the trouble code still remains in the memory.
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STAVIC - 2004.09
4D
57
2. CODING ON TOD CONTROL UNIT

Whats Coding?
An input activity of data for the proper performance by matching specification, devices and system with control unit.
Coding required
1. Replacement of TOD control unit.
2. Adjustment by input error.
Coding method
1. Check and record engine type, axle ratio and tire size.
3. Connect the scanner with diagnosis connector.
5. Select TOD from CONTROL UNIT SELECTION screen
and press ENTER.
6. Read the current memorized specification in TOD control
unit.
7. Compare memorized specification with the checked
record. If not matched, perform a coding.
8. Read again memorized coding specification in TOD
control unit for confirmation of coding.
10. After 5 seconds, turn the ignition switch to ON position.
11. Check coding specification whether it matches with
vehicle or not. If not, perform a coding again.
TOD
STAVIC - 2004.09
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4D
3. DIAGNOSTIC TROUBLE CODE

Code
Description
Action
P1806
CAN Bus OFF
- Check communication line.

- Check the relevant connectors for contact.
- Replace TOD unit if necessary.
P1816
CAN: abnormal TPS signal

- Check engine ECU.
P1814
P1815
CAN: no TPS signal
CAN: no neutral signal

- Check engine ECU.
- Check TCU.
P1817
CAN: no ABS signal
P1821
Open or short to battery in magnetic clutch

coil circuit
P1822
Short to ground in magnetic clutch coil circuit
- Voltage at TCCU pin No.11: 11 ~ 15 V

- EMC resistance: 2.5
P1830
Abnormal rear speed sensor signals
- The indicator is flickering even after IG switch ON.

- The indicator is flickering over 0.5 seconds.
- Check the relevant harnesses.
P1831
P1832

Too low front speed sensor voltage

- Replace sensors if necessary.
- Too low front speed sensor voltage
Too high front speed sensor voltage

- Too high front speed sensor voltage
P1833
Too low rear speed sensor voltage
- Pin voltage: below 0.9 V

- Check the rear speed sensor harness for contact.
- Replace TCCU if necessary.
P1834
Too high rear speed sensor voltage
- Pin voltage: 4.75 ~ 5.25 V

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TOD
STAVIC - 2004.09
4D
Code
P1835
P1836
59
Description
Too low speed sensor reference voltage
Too high speed sensor reference voltage
Action
- Reference voltage: below 4 V
- Reference voltage: over 8 V
P1841
P1842
P1843
P1844
TOD
STAVIC - 2004.09
Open to ground in shift motor circuit
- When TCCU detects the motor failure for 1 second

(Action: IG switch ON)
Short to ground in shift motor output circuit
- Check the relevant harnesses for contact.

- Replace shift motor if necessary.
- When TCCU detects the motor failure for 1 second
(Action: IG switch ON)
Shift system timeout

- 2H-4H: after 1.5 seconds
- 4H-4L: after 3 seconds
Too low position encoder voltage (Stuck in

Low)

- When no signals from the position encoder
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4E
GENERAL INFORMATION
1. SYSTEM OVERVIEW
4WD
Power steering pipe
Sub frame
assembly
Brake assembly
Brake assembly
Front axle
assembly
Power steering assembly
Rear propeller shaft
C.G.P
(Center Gravity Point)
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AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
When the sub frame needs to be removed
* 4WD
* 2WD
1. Engine oilpan replacement.

2. Front axle replacement.
3. Power steering assembly replacement.
1. Engine oilpan replacement.
2WD
Power steering pipe
Sub frame
assembly
Brake assembly
Brake assembly
Stabilizer bar
FRONT SUSP & AXLE
STAVIC - 2004.09

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AFFECTED VIN
4E
2. SPECIFICATION
Suspension type
Double wishbone
Spring type
Coil spring : K = 8.8 (kgf/mm)
Shock absorber type
Gas type
Stabilizer type
Torsion bar : 30
Wheel alignment
30
Caster : 4.5 30
Camber : 0
Toe-in : 0 ~ 4 (mm)
214 (mm)
Axle size
3.7
3.9
4.1
4.3
4.6
4.9
5.4
5.9
Pinion
11
11
11
Gear
41
43
37
47
41
44
43
41
Axle ratio
Number of tooth
Weight
34 (kg)
Length
250.43 (mm)
Oil capacity
1.4 ( )
Specified oil
SAE 90
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FRONT SUSP & AXLE

STAVIC - 2004.09
4E
Dimension (Sub Frame)
FRONT SUSP & AXLE

STAVIC - 2004.09
(Unit : mm)
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4E
3. FRONT AXLE ASSEMBLY

Front axle assembly located between left and right wheel transfer the power from the transmission to both wheel when
4-wheel drive mode is chosen.
At the end of axle sides, axle shafts are connected by constant velocity joint and differential carrier is located in the axle
housing.
Mounting Point
Mounting Point
Left drive shaft
Right drive shaft
Mounting Point
Front propeller shaft
Drive Shaft Assembly

Left and right axle have same over length and removal and
maintenance are easily performed.
Location
Grease capacity
In boot
140 ~ 160g
Out boot
200 ~ 220g
Wheel side
Diffential carrier side
Out boot
CHANGED BY
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In boot
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
4. FRONT SUSPENSION
Coil spring
Upper arm
Knuckle
Stabilizer bar
Lower arm
* Characteristics of front suspension

1. Upper arm mounted relatively high.
2. Coil spring and shock absorber mounted.
3. Maximzed torsion bar effciency.
4. Big rubber bush for better comfort.
5. Minimized king pin offset to decrease vehicle movement.
6. Increased effective wheel base.
7. Diversfied type (2WD, 4WD)
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4E
1) Knuckle (4WD)
1. There are two types of knuckle (4WD, 2WD)
2) Upper arm
1. Minimized gap between coil spring and tire (15mm).

2. Optinized ball joint angle against fluctuating.
3) Lower arm assembly

1. Shock absorber mounted on the bush is
connected to the sub frame with upper arm and
lower arm. It suports the load, at the same time,
it absorbs shock and vibration transferred to the
vehicle.
2. Front mount bush is set on the sub frame and
camber bolt for camber/caster adjustment is
assembled to the lower arm
Cam bolt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
9
5) Shock absorber and coil spring
Shock absorber and coil spring is a device for damping
sudden and rapid motion, as the recoil of a springmounted object from shock.
4) Stabilizer bar assembly
Stabilizer bar
Mounting bracket
Mounting bracket
Stabilizer link
Stabilizer link
Stabilizer bars are part of a cars suspension system.

They are sometimes also called anti-sway bars or anti-roll bars.
Their purpose in life is to try to keep the cars body from rolling in a sharp
turn.
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4E
Structure of Shock Absorber and Coil Spring

1. Coil spring
Specification
4WD
2WD
Spring constant (kg/mm)
8.8 5 %
8.8 5 %
Coil diameter (mm)
16.7
16.6
D1
75.0
75.0
D2
105.0
105.0
Pitch (mm)
85.0
85.0
Number of winding
9.36
9.36
Coil inner diameter (mm)
Number of active winding

C.V.W
(Curved vehicle weight)
7.86
7.86
Height (mm)
256.0
256.0
Weight (kg)
1047 5 %
905 5 %
65.8
68.2
Rightward
Leftward
Strength (kg/mm)
Winding direction
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
11
2. Shock Absorber Assembly

Specification
Max. working distance
540 (mm)
Min. working distance
452 (mm)
Working distance
88 (mm)
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4E

1. COMPONENTS
Front Syspension Assembly
1. Coil spring
16. Upper arm bush

3. Upper bracket
5. Lower bush
15. Upper arm
6. Spring-upper rubber sheet
14. Upper arm ball joint
2. Shock absorber
7. Dust cover
13. Knuckle
9. Stopper-bumper
8. Cam bolt
11. Lower arm
4. bush
12. Lower arm ball joint
10. Lower arm rubber bush
4WD
2WD
23. Hub assembly
13. Knuckle
18. Brake dust shield
22. Brake disk
17. Axle shaft
19. Lock nut
19. Lock nut

13. Knuckle
22. Brake disk
18. Brake dust shield
20. Hub assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
21. Washer
21. Washer
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
13
Front Axle Assembly
Air bleeder
Carrier cover
Ring gear
Axle mounting bracket
Ball bearing
Shim
Pinion gear
Oil seal
Ball bearing
Pinion drive seal
Axle mounting bracket

Axle housing
Snap ring
Shim
Ball bearing
Flage
Lock nut
Inner shaft
Axle shaft assembly
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4E
2. PRECEDING WORK FOR SUB FRAME REMOVAL

1. Install the safety wedge under both rear wheels
(Put the shifting lever in P position and apply the parking brake)
2. Additional safety jack

Because the weight balance move to rear when the sub
frame is removed, safe working condition must be
prepaired.
For this reason, Installing the safety jack to both under
body is important to avoid unexpectable accident.
(The height of safty jack to both side must be same)
16.5 cm
3. The mounting location of suplement lift

The supplement lift is used when you remove or install the sub frame
(Keep in mind the center of gravity of sub frame locate near front axle mounting point)
Front
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
15
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH
LH
Engine insulating
brackets on the sub frame
RH
LH
Engine mounting
brackets on the body
Part number : A9912 008 2B
RH
FRONT SUSP & AXLE

STAVIC - 2004.09
LH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4E
3. REMOVAL OF SUB FRAME

Preceding Work: 1. Secure the frame and remove the tires
2. Remove the front propeller shaft.
Sub Frame Connected Area

1. Remove the power steering pipes
(A: High, Low pressure) and lower arm
shaft (B) at the rear side of syb frame.
2. Remove the front calier (C) and wheel speed sensor (D)
(Fix the caliper and speed sensor on the body. Disconnect the brake
hose clip)
Wheel
Power steering
pipes (Front)
3. Unscrew the power steering pipe (A) mounting bracket

(1, 2) and release them
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4. Unscrew the knuckle upper bolt (E) and

shock absorber lower bolt/nut (F) and then,
remove the shock absorber from knuckle.
FRONT SUSP & AXLE
STAVIC - 2004.09
4E
17
5. Leave mark with a marking painter on the sub frame mounting bolts (19mm - 4EA).
(Tightening torque: 95 ~ 142 Nm)
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm 6EA). And then, drop the lifts slowly.
[Notice]
Apply rubber blocks under sub frame to prevent the frame and other components from damage.
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4E
Rubber block at the front side
Rubber blocks at the rear side
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
19
7. Installation is in the reverse order of removal (Keep the exact mount holes and tightening torque)
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4E
Removal of Sub Frame with Two Colume Lift

1. Since two column type lift does not have supplementary lift, special tool to support the sub frame is required. When
install, apply the special tool with guide pin on the sub frame 3rd cross member and fix the guide bar of special tool
on the 2nd cross member.
2nd cross member

Guide bar
Guide bar
3rd cross member
Guide pin
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
21
2. Do the same preceding work to remove the sub frame (page 624 ~ 626).
3. Remove the sub frame mounting bolts (19mm - 6EA)
Tightening torque
95 ~ 142 Nm
4. Drop the special tool with sub frame slowly.
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4E
4. FRONT AXLE ASSEMBLY

Preceding Work: 1. Remove the tires.
2. Remove the brake calipers and wheel speed sensors (Fix to the body).
Axle Shaft (Drive Shaft)
Coil spring & shock absorber assembly
Upper arm
Knuckle
Brake caliper
Stablilizer
Brake disk
1. Unscrew axle shaft lock nut (30 mm - 1EA) and remove

washer.
[Notice]
Axle shaft lock nut can not be reused. Replace it with new
one when reinstall.
Keep the tightening torque and cock the nut.
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
250 ~ 350 Nm
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
23
2. Unscrew the knuckle upper bolt & nut (19mm - 1EA).

Tightening torque
140 ~ 160 Nm
3. Remove the knuckle from axle shaft and lay outward.
4. Pull out the axle shaft.
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
4E
Axle Housing Oil Seal

Preceding Work: Remove the axle shaft.
1. Unscrew the axle mounting bracket bolts and nut, and remove the axle mounting bracket.
Tightening torque
Mounting bolts (4EA)
10 1.0 Nm
Mounting bolt / nut (1EA)
95 ~ 142 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
25
Axle Housing Assembly

Preceding Work: Remove the sub frame assembly and disassemble the axle shaft from axle assembly.
Axle assembly
Removal of axle shaft
Diffential carrier &

Housing assembly
Bolt
Bolt
Bush
Bush
Washer
Bush
Washer
Nut
Bush
Nut
Washer
Nut
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
4E
1. Unscrew the axle housing mounting bolt on the sub frame and disassemble the axle.
A. Axle mounting bolt/nut
* Keep the right direction of busing when install

Upper bush
Spacer
Lower bush
Color coke
coated
Lower bush
Bracket on the sub frame
B. Axle housing mounting nut - Left

(Tightening torque : 95 ~ 142 Nm)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
C. Axle housing mounting nut - Right

(Tightening torque : 95 ~ 142 Nm)
FRONT SUSP & AXLE
STAVIC - 2004.09
4E
27
5. FRONT SUSPENSION ASSEMBLY

Preceding Work: 1. Remove the tires.
2. Remove the brake calipers and wheel speed sensors (Fix to the body).
Upper Arm Assembly
Upper arm assembly
Upper arm assembly

Upper arm bush
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
4E
1. Remove wheel speed sensor and cable. (10 mm - 1EA, Tightening torque : 6 ~ 8 Nm)
Cable
Speed sensor mounting bolt
2. Unscrew knuckle upper mounting bolt/nut (19 mm - 1EA) and upper arm mounting bracket bolts (14 mm - 4EA) to
remove upper arm assembly.
Knuckle upper bolt (Upper arm ball joint)
Upper arm mounting bracket bolts
Tightening torque : 140 ~ 160 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
29
Lower Arm Assembly

Check point before removal
When you need to remove lower arm assembly, leave a mark on the lower arm mounting bolts (Front /
Rear) for wheel alignment job.
Front
Rear
Lower arm assembly

Lower arm
Ball jont
Ball joint
mounting bolt
Cam bolt
Washer / Bolt
FRONT SUSP & AXLE

STAVIC - 2004.09
Cam bolt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
4E
1. Unscrew the shock absorber lower mounting bolt/nut (1) and stabilizer link low nut (2).
Tightening torque
Shock absorber lower bolt/nut : 110 ~ 130 Nm

Stabilizer link lower nut : 110 ~ 120 Nm
2. Unscrew lower arm ball joint bolt/nut (Knuckle).

Tightening torque
120 ~ 140 Nm
3. Unscrew lower arm bolt/nut (Frame).

Tightening torque
180 ~ 190 Nm
4. Remove lower arm assembly from the sub frame.

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
31
Coil Spring & Shock Absorber Assembly

Preceding Work: Remove the tire and wheel speed sensor.
Coil spring & shock absorber
1. Use a special tool to remove the coil spring

from shock absorber assembly.
2. Keep the specified end gap between shock
absorber and adjust bolt (10 mm).
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
4E
1. Unscrew knuckle upper bolt and then, lay the knuckle

outward.
2. Unscrew the coil spring upper seat mounting nuts (1) at

the top of the shock absorber (10 mm x 3EA).
[Reference]
RH
Under FFH
LH
Under brake oil reservoir tank
Tightening torque
30 ~ 45 Nm
3. Unscrew the shock absorber lower bolt and pull upward as putting down the assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
33
Stabilizer Bar Assembly
Stabilizer bar assembly
Stabilizer bar assembly
Mounting bracket
Mounting bracket
Stabilizer bar link
FRONT SUSP & AXLE

STAVIC - 2004.09
Stabilizer bar link
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
4E
Stabilizer bar link
Stabilizer bar link
Mounting bracket
2. Unscrew the stabilizer bar cap bolts (3) and

remove the stabilizer bar.
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
110 ~ 120 Nm
Mounting bracket
1. Unscrew the stabilizer bar link upper nut (1) and

lower bolt (2) to remove the link.
Tightening torque
Upper bolt : 60 ~ 80 Nm
Lower bolt : 110 ~ 130 Nm
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
35
Knuckle Assembly
Preceding Work: 1. Removal of tires.
2. Removal of brake caliper and wheel speed sensor (Fix the sensor to the body).
Knuckle assembly
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
36
4E
1. Unscrew the lock nut (1) and brake disk mounting bolts
(2: 5 mm - 2EA) and then, remove the disk from knuckle
assembly.
Tightening torque
8 ~ 12 Nm
2. Unscrew the brake dust shield mounting bolts (3EA).

Tightening torque
8 ~ 12 Nm
3. Remove the knuckle mounting bolts in the following order

A. Tie rod end nut (19mm - 1EA)
: Remove the pin first (A)
[Notice]
Keep the tightening torque and if the position of pin hole is
improper, rotate the nut to the tightening direction.
Tightening torque
35 ~ 45 Nm
B. Lower arm bolt nut (19mm - 1EA)

: Release the bolt first. Remove after upper arm bolt
(C) is removed.
C. Upper arm bolt/nut (19mm -1EA)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
FRONT SUSP & AXLE

STAVIC - 2004.09
4E
37
4. Remove the front wheel nuckle from the drive shaft.

(Replace the brake disk lock nut with new one for every disassembly and do the cocking job for the nut)
FRONT SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
38
4E
TROUBLE DIAGNOSIS
Symptom
Vehicle rolling
Abnormal noises
Poor riding
Cause
Broken stabilizer bar
Replace
Faulty shock absorber
Replace
Loosening mountings
Re-tighten
Damaged or worn wheel bearing
Replace
Damaged shock absorber
Replace
Damaged tire
Replace
Over inflated tire

Loosened wheel bolt
Vehicle pulls to right or left
Hard steering
Replace
Worn bushing
Replace
Deformed arm assembly
Replace
Worn bushing
Replace
Bent or broken coil spring
Replace
Incorrect front wheel alignment
Incorrect front wheel alignment

Worn or loosened lower arm bushing
CHANGED BY
AFFECTED VIN
Tighten as specified torque
Damaged tire
Faulty power steering
EFFECTIVE DATE
Replace
Replace
Insufficient tire pressure
Vehicle bottoming
Pressure adjust
Bent or broken coil spring
Excessive resistance of lower arm ball joint
Steering instability
Action
Worn or broken coil spring
Repair
Replace
Adjust
Repair or replace
Repair
Re-tighten or replace
Replace
FRONT SUSP & AXLE

STAVIC - 2004.09
4F
REAR AXLE CARRIER (MODULE)

1. SYSTEM OVERVIEW
Shock absorber
Camber link
Coil spring
Axle shaft
Wheel carrier
Tension link
Track rod
Thrust link
Stabilizer
Axle mounting
Front View
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
Rear View
Axle mounting
Rear brake cable
Rear Axle & Axle Shaft

Rear axle
Axle shaft
Spring link
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
2. SPECIFICATION
Suspension type
Multi-link
Spring type
Coil spring
K=120 kgf/mn
Gas
Shock absorber type

Stabilizer type
Wheel alignment
Torsion bar
14
Toe-in
0.04 0.08
Camber
-1.0 0.5
Diameter (Axle) (mm)

Gear ration
Number of tooth
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
230
37
3.9
4.1
4.3
4.6
4.9
5.4
5.9
Pinion
11
11
11
Gear
41
43
37
47
41
44
43
41
Weight (kg)
40
Length (mn)
250.43
Oil capacity ( )
1.7
Specified oil
TOTAL-ISU EP- B85W-90
REAR SUSP & AXLE

STAVIC - 2004.09
4F

1. Move the 2nd raw seat to te front end and unscrew the
rear shock absorber upper cover mounting screw (1).
2. Remove the rear shock absorber upper nut (2),

washer and bush.
Keep the specified end gap between shock absorber.

(A: 7 ~ 12 mm)
Tightening torque
REAR SUSP & AXLE

STAVIC - 2004.09
30 ~ 40 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
3. Remove the rear propeller shaft.
4. Disconnect the parking brake cable.
5. unscrew the frame mounting bolt on the rear axle

carrier module front side.
6. Remove the wheel speed sensor (LH/RH).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
7. Unscrew the stabilizer mounting bolt (A) and remove it from the vehicle.
A
8. Remove rear frome mounting bolt (B) at the rear axle carrier module.
B
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4F
9. Remove the rear axle carrier module from the vehicle.
Front
Rear
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
REAR SUSPENSION SYSTEM

1. SYSTEM OVERVIEW
Camber link
Tension link
Track rod
Thrust link
Stabilizer bar
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4F
Spring link
Wheel carrier
Stabilizer link
Coil spring
Shock absorber
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
11
2. COMPONENTS
1) Rear Shock Absorber
Keep the suitable distance when compressed and
expanded.
Minimum length is 10 mm longer than the minimum length
under compression.
Specification
Max. length
Min. length
Working distance
487 mm
326.6 mm
160.4 mm
Marking Point
X : Part No.
Y : Lot Number
Ex : 3
12
12 ......... Day
3 ........... Month
2003 ...... Year
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4F

1. Move the 2nd raw seat to the front end and unscrew
the rear shock absorber upper cover mounting bolt (1).
2. Remove the rear shock absorber upper nut (2), washer

and bush.
3. Unscrew the lower mounting nut on the spring link (17 mm).
Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
50 ~ 60 Nm
REAR SUSP & AXLE

STAVIC - 2004.09
4F
13
4. Remove the shock absorber as pushing upward.
Shock absorber assembly
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4F
2) Coil Spring
Steel for high tensional spring is adapted.
Maintain more than 20 mm of freeplay when compressed.
Spring seat applied.
Specification
4WD
C.V.W
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Part Number
45110-21000
Spring constant (kg/mm)
12.0 5%
Coil diameter (mm)
15.9
Coil inner diameter (mm)
69.1
Pitch (mm)
85.0
Number of winding
9.55
Number of active winding
8.35
Height (mm)
250
Weight (kg)
880.0
Strength (kg/mm/mm)
62.1
Winding direction
Right
Spring length (mm)
323.3
REAR SUSP & AXLE
STAVIC - 2004.09
4F
15

Compress the coil spring with special tool and then, disassemble the spring.
[Notice]
For easier removal, remove the spring seat first.
[Notice]
Pay attention to use special tool and coil spring.
Sudden release of coil spring could cause a serious accident.
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4F
3) Thrust Link / Tension Link

Thrust Link
Tension Link
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
17

Thrust Link
1. Unscrew the thrust link mounting bolts (19 mm-2EA) and remore the link.
2. When install, apply two washers to the thrust link mounting bolt/nut (A. Wheel carrier)
Tightening torque (A, B)
70 8 Nm
A. Wheel carrier
B. Body
[Reference]
1. Keep the right position when reinstall (faced outward).
2. Apply the longer bolt to the thrust link wheel carrier side.
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4F
Tension Link
1. Unscrew the tension link mounting bolt (B. Body-19 mm).

2. Unscrew the tension link mounting bolt (A. Wheel carrier-19 mm).
Tightening torque
Body: 70 8
Wheel carrier: 70 8
A. Wheel carrier
B. Body
[Reference]
1. Keep the right position when reinstall.
2. Apply the longer bolt to the tension link wheel carrier side.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
19
4) Track Rod
1. Unscrew the track rod mounting bolt (A. Body-19 mm)

Tightening torque
70 8
2. Unscrew the track rod mounting bolt (B. Wheel carrier-17 mm)
Tightening torque
A. Body
REAR SUSP & AXLE

STAVIC - 2004.09
30 5
B. Wheel carrier
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4F
5) Camber Link
1. Unscrew the camber link mounting bolt (B. Body-19 mm)

Tightening torque
70 8
2. Unscrew the camber link mounting bolt (A. Wheel carrier-19 mm)
Tightening torque
70 8
A. Wheel carrier
B. Body
[Notice]
1. When install, apply two washer to the camber link mounting
bolt/nut (A. Wheel carrier).
2. Keep the right position when reinstall.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
21
6) Stabilizer Bar / Stabilizer Link

Stabilizer Link
Stabilizer bar
Stabilizer link
1. Unscrew the stabilizer link upper mounting bolt (17 mm) and lower mounting bolt (13 mm).
A
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4F
Stabilizer Bar
Preceding work: Removal of stabilizer link
- Remove stabilizer bar mounting bracket to seperate the stabilizer bar from the vehicle.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
23
7) Spring Link
1. Compress the spring with special tool for easier removal and installation.
2. Unscrew the wheel carrier mounting bolt (A), stabilizer link mounting nut (B) and shock absorber mounting nut (C).
Wheel carrier: 20 Nm
Tightening torque
Stabilizer link: 120 Nm

Shock absorber: 55 Nm
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
4F
3. Unscrew the spring link mounting bolt on the rear axle

carrier and remove the spring link.
Spring Link
Wheel carrier
Shock absorber
Stabilizer link
Body
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
25
8) Wheel Carrier Assembly

1. Remove the wheel speed sensor.
2. Remove the brake caliper.
3. Unscrew the brake disk mounting unt (2 EA) and remove the disk.
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
4F
4. Remove the lock nut (30 mm).

[Notice]
Lock nut can not be reused. Replace by every disassembly.
5. Remove the parking brake shoe (Refer to the wheel &

tire).
6. Remove the parking brake cable from the wheel carrier.
7. Unscrew the wheel carrier mounting nut and remove it

from the spring link.
8. unscrew the tension link, track rod, thrust link mounting
nuts on wheel carrier.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
27
9. Remove the wheel carrier from drive shaft.
A. Front view
REAR SUSP & AXLE

STAVIC - 2004.09
B. Rear view
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
4F
REAR AXLE HOUSING & AXLE SHAFT

1. SYSTEM OVERVIEW
Front mounting point
Drive shaft
Rear mounting point
Axle housing
Specification
Axle size
214
3.3
3.9
4.1
4.3
4.6
4.9
5.4
5.9
Pinion
13
11
11
Gear
43
43
37
47
41
44
43
41
Gear ratio
Number of tooth
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
29
2. REAR AXLE DIFFERENTIAL ASSEMBLY

Sectional Diagram
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
4F
1. Rear axle housing
19. Spring pin
2. Gear set (HAG 230, i = 3.31)
20. Bearing cover
3. Gear set (HAG 230, i = 3.54)
21. Bearing cover shim
4. Gear set (HAG 230, i = 3.73)
22. Differential side seal
5. Gear set (HAG 230, i = 3.91)
23. Bearing cover O-ring
6. Gear set (HAG 230, i = 4.11)
24. SOC/HD bolt
7. Gear set (HAG 230, i = 4.27)
25. Drive pinion shim
8. Gear set (HAG 230, i = 4.56)
26. Rear drive pinion bearing assembly
9. Gear set (HAG 230, i = 4.89)
27. Drive pinion tube spacer
10. Differential spider gear
28. Drive pinion support disk
11. Differential side gear
29. Drive pinion front bearing assembly
12. Spiral washer
30. Drive pinion seal
13. Differential spider shaft
31. Drive pinion flange assembly
14. Differential case - i = 3.31 - 3.73
32. Two-welled side lock nut
15. Differential case - i = 3.91 - 4.89
33. Inner flange assembly
16. Differential thrust washer
34. Inner axle shaft shim
17. Differential side bearing assembly
35. Differential assembly snap ring & shaft
18. Ring gear safety bolt
36. Rear axle housing cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
31

Rear Axle Shaft
Preceding work: Removal of wheel and tire
1. Unscrew rear axle shaft mounting bolts from axle housing
(6 EA).
Tightening torque
Initial: 70 ~ 80 Nm
Secondary: 90 5
[Notice]
Replace the bolts by every removal
2. Unscrew lock nut (30 mm) from wheel disk side and
remove the axle shaft.
Tightening torque
200 ~ 240 Nm
[Notice]
Replace the lock nut to new one by every disassembly.
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
4F
Rear Axle Housing

Preceding work: Removal of rear axle shaft
1. Support the axle housing with mounting jack.

2. Unscrew one front mounting bolt and two rear mounting bolts to remove the axle housing from the rear sub frame.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
33
Replacement of Radial Sealing and

O-ring
Preceding work: Removal of rear axle housing
1. Drain oil in the axle housing.
2. Remove the axle mounting damper
[Notice]
Damper bolt should be replaced by ecery removal.
Tightening torque
90 110 Nm
3. Remove the axle housing cover and damper bracket.
4. Remove the connecting flange snap ring with special tool.
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
4F
5. Pull out the inner flange.
6. Remove the radial sealing with a tool.
7. To replace the O-ring, unscrew the side bearing cover

mounting bolts.
Tightening torque
20 4 Nm
8. Remove shim and replace the O-ring.
Inner flange
Radial sealing
Shim
O-ring
Snap ring
Back lash adjust shim
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
REAR SUSP & AXLE

STAVIC - 2004.09
4F
35
Replacement of Radial Sealing and

O-ring on Propeller Shaft Flange
1. Unscrew the lock nut with socket wrench (30 mm).
Tightening torque
120 Nm
[Notice]
Replace the lock nut to new one by every disassembly.
2. Remove the radial sealing with a tool.
Lock nut
Inner flange
Radial sealing
REAR SUSP & AXLE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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4G
GENERAL INFORMATION
1. OVERVIEW
The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type
and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in pump controls the
discharging pressure.
The rotary valve in rack and pinion gear directs the oil from the power steering pump to one side of rack piston.
The integrated rack piston converts the hydraulic pressure to linear movement.
The operating force of rack moves the wheels through tie rod, tie rod end and steering knuckle.
Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs
very high steering force.
In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack
through pinion gear combined to rack gear.
2. SPECIFICATION
Item
Steering wheel
Specification
Number of spoke
4 spokes
Outer diameter
390 mm
Rotation
Gear box
3.6 rotations
Type
Rack & Pinion
Gear ratio
Steering
angle
Inner
37 42
Outer
32 56
Tilting angle
2
5.882 m
Minimum turning radius

Oil pump
Oil
Type
Displacement
11.3 cc/rev
Max. pressure
90 bar
Specified oil
Capacity
POWER STEERING
STAVIC - 2004.09
Clustered in reservoir tank
ATF Dexron II, III

Approx. 1 liter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4G
GENERAL INFORMATION
1. OVERVIEW
The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type
and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in pump controls the
discharging pressure.
The rotary valve in rack and pinion gear directs the oil from the power steering pump to one side of rack piston.
The integrated rack piston converts the hydraulic pressure to linear movement.
The operating force of rack moves the wheels through tie rod, tie rod end and steering knuckle.
Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs
very high steering force.
In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack
through pinion gear combined to rack gear.
2. SPECIFICATION
Item
Steering wheel
Specification
Number of spoke
4 spokes
Outer diameter
390 mm
Rotation
Gear box
3.6 rotations
Type
Rack & Pinion
Gear ratio
Steering
angle
Inner
37 42
Outer
32 56
Tilting angle
2
5.882 m
Minimum turning radius

Oil pump
Oil
Type
Displacement
11.3 cc/rev
Max. pressure
90 bar
Specified oil
Capacity
POWER STEERING
STAVIC - 2004.09
Clustered in reservoir tank
ATF Dexron II, III

Approx. 1 liter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4G
3. COMPONENTS
Steering wheel
Power steering
pump assembly
Column shaft
Power steering
oil pipe & hose
Lower shaft
Tie rod end

assembly
Tie rod end

assembly
Steering gear
box assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
Power Steering Gear Box Assembly
Gear box assembly

Clamp mounting
Tie rod end
Tie rod end
Tie rod
Tie rod
Boot
Bush mounting
The power steering gear consists of power cylinder and

control valve.
The power cylinder has cylinder, piston and piston rod.
The control valve directs the oil to one end face of the piston to enhance the steering force.
The control valve controls the directions and operations of
power cylinder.
Boot
Additionally, the safety check valve is installed so that the

system can be operated manually when the system is
defective.
Sub frame mounting
(4 points)
Clamp mounting (2EA)

Bush mounting (2EA)
Power Steering Pump

The vane type pump that is connected to engine by belt is
used for the power steering system. This pump generates
and controls a proper hydraulic pressure and flows by using the flow control valve and pressure relief valve.
The flow control valve regulates the excessive amount of
discharging oil. When the steering wheel is stationary or
the oil circuit is blocked, the pressure relief valve returns
the over pressurized oil to the oil reservoir.
Oil Reservoir
The oil reservoir sends the oil to the power steering pump
and receives the oil from the power steering gear.
The oil level in the reservoir depends on the steering wheel
positions. therefore, measure the oil level when the steering wheel is positioned at straight ahead direction (neutral).
POWER STEERING
STAVIC - 2004.09
Steering pump
Reservoir tank
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4G
GENERAL INSPECTION
1. STEERING WHEEL
Power Steering Wheel Free Play
Check
1. Start the engine and place the wheels at straight ahead
direction.
2. Turn the steering wheel until the tires starts to move and
measure the distance on the circumference of the
steering wheel.
Specified value
30 mm
[Notice]
If the free play is out of the specified value, check the
clearance in steering column shaft connection and steering
linkage. Replace or repair if necessary.
Steering Effort Check

1. Park the vehicle on a paved and flat ground and place
the front wheels at straight ahead direction.
2. Start the engine and let it run around 1,000 rpm.
3. Install the spring scale on the circumference of the
steering wheel and measure the steering effort in both
directions.
Tightening torque
Below 3.0 kg
[Notice]
The difference between both sides should be within 0.6 kg.
Steering Angle Check

1. Place the front wheel on a turning radius measuring tool.
2. Turn the steering wheel to the its both ends and measure
the maximum steering angle.
Specified value
Inner
37 42
Outer
32 56
[Notice]
If the free play is out of the specified value, check and adjust
the toe-in.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
Power Steering Gear Preload

Adjustment
1. Place the steering wheel at straight ahead direction.
2. Lift up the vehicle very carefully.
3. Remove the adjusting plug lock nut.
4. Measure the torque of adjusting plug.
5. If the measured torque is out of range, adjust it to the

specified value.
Place the rack gear in center position.
Tighten the adjusting plug by 100 kg.cm
Turn the pinion gear to move the rack gear between
both ends by 5 times.
Remove the adjusting plug.
Tighten the adjusting plug by 45 ~ 55 kg.cm
Release the adjusting plug by 67.5.
6. Tighten the adjusting plug lock nut.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4G
2. OIL PUMP PRESSURE

Check the oil pump pressure to locate any defect in oil pump.
[Notice]
Before checking the pressure, check the oil level and belt
tension. Prepare the empty container to collect the spilled
oil during the service.
1. Unscrew the pressure line fitting in power steering pump.

2. Install the pressure gauge between the power steering
pump and the power steering oil pressure line.
3. Place the shift lever to neutral position.
4. Apply the parking brake.
5. Open the valve in pressure gauge.
6. Start the engine and let it run at idle speed.
7. Turn the steering wheel several times so that the oil
temperature reaches to normal operating level. (50 ~ 80C)
8. Fully close the valve in pressure gauge and measure the
oil pressure.
[Notice]
To prevent internal damage, do not close the gauge valve
over 10 seconds.
Pump relief valve pressure
89 ~ 97 kg/cm2
9. Measure the oil pressure with the gauge valve fully closed.
Pump pressure at no load
3 ~ 5 kg/cm2
10. If the pump pressure is in specified range, the pump is

normal. If not, replace the power steering pump.
3. OIL LEVEL CHECK

The power steering oil level have to be checked by two
conditions; one is checked at normal operating temperature,
and the other one is checked when it is cooled. If the difference between two measurements is below 5 mm and the level
is between HOT and ADD level, its normal. If it is over 5 mm,
bleed air from the system.
1. Place the vehicle on a flat ground and start the engine
and let it run at idle speed.
Displacement of oil level
HOT
HOT
ADD
ADD
2. Turn the steering wheel several times so that the oil

temperature reaches to normal operating level.
3. Place the steering wheel at straight ahead direction.
Engine off
Engine on
4. Measure the oil level in the power steering oil reservoir.

5. Adjust the oil level between HOT and ADD.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
4. OIL CHANGE
1. Lift up the vehicle carefully.
2. Disconnect the oil supply hose from the power steering
pump.
3. Drain the oil from the power steering oil reservoir.
4. Connect the oil supply hose to the power steering pump.
5. Disconnect the oil return line from the power steering oil
reservoir.
6. Periodically crank the starting motor and turn the steering
wheel to its both ends to drain the oil in the reservoir
through the return line.
7. Connect the return line to the steering oil reservoir.
8. Fill the oil into the steering oil reservoir to the specified
level.
H. MAX - when the oil is hot
9. Bleed the air from the system.
C. Leverage value - when the oil is cooled

ADD. MIN
[Notice]
Always keep the oil level over the ADD line.
5. BELT TENSION CHECK AND

ADJUSTMENT
1. Check the belt for wear, crack and damage. Replace it if
needed.
2. Press the center of belt with around 10 kg of force and
check the deflection.
[Notice]
If the deflection is too large:
Replace the auto tensioning assembly.
Check the belt and replace.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4G
6. AIR BLEEDING
After the power steering repairing, do the air bleeding job.
Checking bubble is foune
1. Lift up the vehicle ( A load to the steering wheel) .

2. Add the specified oil in the reservoir tank up to max level.
3. Turn the steering wheel to its both ends several times.
4. Check if bubble is found and do the previous job several times.
5. If bubble can not be found, add the specified oil in the reservoir tank to the specified level.
6. Start the engine and operate the second and third job to air bleed clearly.
[Notice]
If the air bleeding is not properly performed, the life span of
the power steering pump may be shortened.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
11

1. COMPONENTS
Airbag
Lock nut
Bolt
Steering wheel
Washer
Wheel damper
Cover
Bolt
Power steering high pressure hose
Column shaft
Lower shaft
Power steering return pipe
Bolt
Cot pin
Nut
Bolt
Nut
Tie rod
Tie rod end
Power steering gear assembly
Bolt
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4G
Tightening Torque
Kgfxxm
Nxx m
Steering column mounting bolt
2.0 ~ 2.5
20 ~ 25
Steering wheel and column shaft lock nut
4.0 ~ 6.1
40 ~ 60
Airbag module mounting bolt
0.7 ~ 1.1
7.0 ~ 11
Steering column and lower shaft mounting bolt
1.8 ~ 2.5
18 ~ 25
Steering gear box and sub frame mounting bolt
7.0 ~ 9.0
70 ~ 90
Steering box and lower shaft mounting bolt
1.8 ~ 2.5
18 ~ 25
Tie rod end nuckle
3.5 ~ 4.5
35 ~ 45
Tie rod end lock nut
6.5 ~ 8.0
65 ~ 80
Steering gear box and high pressure pipe
1.2 ~ 1.8
12 ~ 18
Steering gear box and return(Low pressure) line
1.2 ~ 1.8
12 ~ 18
Power pump bracket and timing gear case cover
2.0 ~ 2.3
20 ~ 23
Power pump and high pressure pipe
4.0 ~ 5.0
40 ~ 50
Return line and mounting bolt
1.2 ~ 1.8
12 ~ 18
Item
Power steering column
shaft
Power steering gear

box
Power steering pump
mounting bolt
Power steering oil pipe
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
13
2. COLUMN SHAFT AND LOWER SHAFT

1. Disconnect the battery negative cable and place the tires to straight ahead direction.
2. Unscrew the screws at both sides of steering wheel and remove the horn pad (air bag module). Disconnect the
airbag module connector.
3. Unscrew the steering wheel lock nut and remove the wheel with special tool.
[Notice]
Leave marks on the column shaft and steering wheel for
correct installation.
4. Remove the instrument lower panel and disconnect all related connectors.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4G
5. Unscrew the steering column cover bolts and remove it.
6. Disconnect five connectors in the cover.
1. Key switch connector
4. Airbag connector
2. Key hole lamp connector
5. Steering wheel angle sensor
3. Contact coil connector
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
15
7. Unscrew the contact coil mounting screw and remove it from multi function switch.
8. Disconnect both left and right connectors of multi function switch and unscrew the multi function switch mounting
bolt to disassemble from steering column.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4G
9. Leave marks on the column shaft and lower shaft.

10. Unscrew the column shaft upper mounting bolts(A) and lower shaft mounting bolt.
Column shaft upper mounting bolts (4-EA)
Column shaft upper mounting bolts (2-EA)
11. Remove the steering column shaft from lower shaft.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
17
12. Unscrew the lower shaft housing floor mounting bolt(A) and lower shaft mounting bolt on the steering gear box.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4G
3. STEERING GEAR BOX

Preceding Work
1. Install the safety wedge under both rear wheels
(Put the shifting lever in P position and apply the parking brake)
2. Additional safety jack

Because the weight balance move to rear when the sub
frame is removed, safe working condition must be
prepaired.
For this reason, Installing the safety jack to both under
body is important to avoid unexpectable accident.
(The height of safty jack to both side must be same)
16.5 cm
3. The mounting location of suplement lift

The supplement lift is used when you remove or install the sub frame
(Keep in mind the center of gravity of sub frame locate near front axle mounting point)
Front
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Rear
POWER STEERING
STAVIC - 2004.09
4G
19
4. Remove the engine lnsulating brackets from the front sub frame as the
engine hung by an additional lift (crane)
5. Install the engine mounting bracket
Before removal of sub frame, install the special tool (Engine mounting
brackets) on the body frame
RH
LH
Engine insulating
brackets on the sub frame
RH
LH
Engine mounting
brackets on the body
Part number : A9912 008 2B
RH
POWER STEERING
STAVIC - 2004.09
LH
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4G

1. Remove the power steering pipes
(A: High, Low pressure) and lower arm
shaft (B) at the rear side of syb frame.
2. Remove the front calier (C) and wheel speed sensor (D)
(Fix the caliper and speed sensor on the body. Disconnect the
brake hose clip)
Wheel
Power steering
pipes (Front)
3. Unscrew the power steering pipe mounting

bracket (1, 2) and release them
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4. Unscrew the knuckle upper bolt (E) and

shock absorber lower bolt/nut (F) and then,
remove the shock absorber from knuckle.
POWER STEERING
STAVIC - 2004.09
4G
21
5. Leave mark with a marking painter on the sub frame mounting bolts.
6. Locate two sypplement lifts under sub frame (Front/Rear) and unscrew the sub frame mounting bolts (19mm 6EA).
And then, drop the lifts slowly.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
4G
7. Unscrew the clamp mounting bolt of stabilizer bar and fix to the upper side of axle flange.
8. Remove the coat pin and nut(1), and unscrew the gear box clamp bolt(2) and bush mounting nut(3).
1. Coat pin and nut
2. Clamp mounting bolt
Tightening torque
25 ~ 30 Nm
Tightening torque
100 ~ 130 Nm
A. Stabilizer
2. Clamp mounting bolt

1. Tie rod end
1. Tie rod end
3. Bush mounting nut

Tightening torque
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Upper bolt : 70 ~ 90 Nm
Lower bolt : 70 ~ 90 Nm
POWER STEERING
STAVIC - 2004.09
4G
23
9. Disassemble the steering gear box as shown below with arrow mark.
Gear box mounting bolt(Clamp)

: 70 ~ 90 N.m
Sloted nut
: 25 ~ 30 N .m
POWER STEERING
STAVIC - 2004.09
Sloted nut
: 25 ~ 30 N.m
Gear box mounting bolt
(Bushing)
: 70 ~ 90 N.m
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
4G
Disassembly and Reassembly of

Steering Gear Box
Disassembly
* Describes the basic power steering assembly.
1. Remove the tie rod end boot (a).
2. Remove the feed lines (2) from the cylinder tube in gear
box.
3. Remove the feed lines (1) from the valve housing in gear
box.
4. Unscrew the lock nut (1) and remove the plug (2) and
spring (3).
5. Remove the dust cover (1) and retainer ring (2).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
25
6. Remove the pinion dust cover (lower, 3) and unscrew the

pinion lock nut (4).
[Notice]
Before removing the pinion lock nut, make sure to lock the
pinion gear to prevent it from damaging.
7. Remove the steering pinion (5) from pinion bearing by

tapping the bottom end of steering pinion with a flat drift
and plastic hammer.
[Notice]
Align the center of the drift and the bottom end of steering
pinion.
8. Remove the pinion bearing (6) by tapping it with a long

and flat head drift and plastic hammer.
9. Remove the pinion shaft seal (7), needle bearing (8) and
retaining ring (9).
[Notice]
Do not disassemble the power steering gear housing and
rack gear. Replace it as an assembly if needed.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
4G
Reassembly
1. Install the steering pinion gear.
1) Install the retaining ring.
2) Install the needle bearing.
3) Install the pinion shaft seal by tapping it with a long
and flat end drift.
2. Tighten the steering pinion lock nut (4) with a specified

tightening torque.
[Notice]
Make sure that the pinion bearing is not offset with the
steering pinion lock nut.
3. Tighten the steering pinion dust cover (5) with a specified

tightening torque.
1) Install the retaining ring (6).
2) Install the plastic dust cover (7).
4. Install the rack bearing.

Install the adjusting spring.
Tighten the adjusting plug with a specified tightening
torque.
Tighten the lock nut.
Adjust the preload of steering gear.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
27
5. Install the hydraulic pipes.
6. Install the tie rod end boot.

[Notice]
Apply grease into the ball joint of tie rod end and the boot.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
4G
Inspection
Rack Gear Shaft
1. Check the rack gear for deformation and damage.
Place the V-blocks (1) on the flatten plate.
Put the rack gear (2 and 4) on the V-blocks.
Measure the straightness of rack gear with a dial
gauge.
Check the rack gear for abnormal wear and damage.
2. Check the steering pinion gear for damage.

Check the pinion gear (1) for abnormal wear and
damage.
Check the bearing (2) for looseness and operation.
3. Check the tie rod end and the rack and pinion bellows for
damage.
Check the tie rod end boot (1) for crack and abnormal
wear.
Check the rack and pinion boot (2) for crack and
abnormal wear.
4. Check the steering gear housing (a) for crack, distortion

and abnormal wear.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
29
5. Check the tie rod end and the tie rod ball joint for damage.
Check the tie rod end ball joint for operation.
Check the tie rod ball joint for operation. Check the
tie rod for deflection due to its weight.
6. Replace all the defective components with new ones.
7. Check the tie rod end and the rotating area (1) of tie rod
ball joint for damage.
8. Check the tie rod end and the rack and pinion boot for
crack and abnormal wear.
9. Check the metal components for wear.
Check the pinion gear for abnormal wear and damage.
Check the rack gear for abnormal wear and damage.
Check the steering gear housing for wear and damage.
10. Check the bearings and oil seals for damage.

Check the pinion shaft seal (1) for wear and leakage.
Check the needle bearing (2) for wear.
Check the steering pinion bearing (3) for wear.
11. Replace all the defective components with new ones.
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
4G
4. STEERING GEAR PUMP AND OIL PIPE

Power Steering Gear Pump Assembly
Preceding Work: 1. Disconnect the battery negative cable.
2. Remove fan belt and drain the power steering oil.
1. Unscrew th pump mounting bolt/nut(1) and disconnect
the oil pipes(2, 3).
Tightening torque
Mounting nut (1): 2.0 ~ 2.3 kgm

Oil pump (2): 4.5 ~ 5.0 kgm
2. Remove the pump clip and disassemble the pump from reservoir tank.
Mounting clip
Reservior tank
Mounting clip
Pump assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
31
Power Steering Oil Pipes

Preceding Work: Drain the power steering oil.
1. Disconnect the oil pipes(High, low pressure) frame the steering oil pump, power steering and sub framegear box.
1.Oil pump
2. Gear box
Oil return pipe

(Low pressure)
High pressure pipe
Low pressure pipe
Oil supply pipe

(High pressure)
Pipe mounting bolts
Sub frame
[Notice]
If two oil pipes ( High, Low pressure ) are installed as
changed, abnormal vibration is detected through steering
handle and this damage to the power steering system.
(Smaller hole diameter for high pressure pipe)
POWER STEERING
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
4G
- Layout of high and low pressure pipe
Front
Rear
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
33
TROUBLE DIAGNOSIS
Symptom
Hard steering
Cause
Lack of lubrication
Abnormal wear or binding of steering ball joint
Damaged or faulty steering gear
Improper preload of steering pinion
Faulty steering shaft joint
Steering fluid leaks
Lack of fluid or air-in system
Faulty steering oil pump
Action
Rubricate & Replace
Replace
Replace gear assembly
Adjust
Replace
Repair or replace
Replenish or bleed
Replace
Steering pulls to one
Damaged or loosened pump drive belt
Adjust or replace
side
Clogging oil line
Repair or replace
Damaged wheel or tire
Repair or replace
Faulty suspension system
Repair or replace
Damaged steering linkage
Repair
Excessive wheel play
Damaged wheel and tire
Repair or replace
Faulty brake system
Repair or replace
Repair or replace
Worn steering gear

Worn or damaged steering ball joint
Loosened steering gearbox bolts
Poor return of steering

wheel
Damaged or binding steering ball joint

Improper preload of steering pinion

Replace
Retighten
Replace
Repair or replace
Repair or replace
Steering wheel vibration
Damaged steering linkage
Replace
(Shimmy)
Loosened steering gearbox mounting bolt
Abnormal noise from

steering system
Damaged or binding steering ball joint
Replace
Worn or damaged front wheel bearing
Replace
Repair or replace
Repair or replace
Loosened steering gearbox mounting bolt

Faulty steering gear
Steering column linterference
Loosened steering linkage
Damaged or loosened oil pump drive belt

Replace
Retighten
Adjust or replace
Retighten
Loosened oil pump mounting bolt
Retighten
Faulty oil pump
STAVIC - 2004.09
Retighten
Loosened oil pump bracket
Air-in system
POWER STEERING
Retighten
Bleed
Replace
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
4G
Symptom
Abnormal noise while

the operation
Cause
Action
Loosen steering column mounting nut or bad tightening
Retighten
Worn or damage steering shaft bearing

Loosen inner shaft pinch bolt
Replace steering column

Retighten
Excessive steering force
Worn or damaged steering shaft bearing
Ignition switch bad

turning
Defective lock cylinder
Defective ignition key
Replace ignition key
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
POWER STEERING
STAVIC - 2004.09
4G
35

661 589 13 33 00
Ball joint puller
POWER STEERING
STAVIC - 2004.09
Application
Removal of the upper and lower
end assemblies of front
suspension
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
Tire And wheel Balancing
There are two types of the tire and wheel balancing: static
and dynamic.
Static balance is the equaldistribution of weight around
the wheel. assemblies that are statically unbalanced cause
a bouncing action called wheel tramp. This condition may
eventually cause uneven tire wear.
Dynamic balance is the equal distributio of weight on eeach
side of the centerline so that when the assembly spins
there is no tendency for it to move frim side to side . Assemblies that are dynamically unbalanced may cause
wheel shimmy.
General Balance Precautions

Remove all deposits of foreign material from the inside of
the wheel.
[Caution]
2. Breaker
A cord belt between tread and carcass prevents
damages of inner code due to outer shock and
vibration.
3. Carcass
This major part made by pilling code papers of strong
synthetic fiber forms a structure of tire. Since it
maintains tire pressure and endures applied load and
shock to tire, it should have a high anti-fatigue
characteristic.
4. Side Wall
It is provided to improve the comfortable driving by
protecting carcass and cushion movement.
5. Bead
A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord
papers. It fixes tire to a rim.
Remove stones frim the gread in order to avoid operator

injury during spin balancing
Width
Inspect the tire for any damage. Balance the tire according to the equipment manufacturers recommendations.
Structure of Tubeless Tube

Inside
Diameter
Outside
Diameter
Width
Height
The tire structure is different slightly according to the types

of the tire but a various type of the tire has the common
structure as following;
1. Tread
A part (that contacts) road surfaces directly is fixed
on the outsude of carcass and breaker.
It is a strong rubber coat made of high anti-abrasion
rubber. Its running performance depends on is surface
profile.
WHEELS & TIRE
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
Conventions for Radial Tire

P
225
65
16
The Relations Between Inflation

Pressure and Tire
104 T
Max Speed :
190 km/h
Excessive Air-Pressure
Life
(%)
Load Index :
900 kg
Insufficient Air-Pressure
Rim Diameter : 16 inch.

Radial Tire
Air-Pressure to Standard air-Pressure (%)
Aspect Ratio = (Section Height

Section Width) x 100 : 65 %
The Relations Between Load

and Tire
Section Width : 225 mm

Passenger Car
Max Speed Symbol
Load Index
Symbol
Limit Speed
(km/h)
Symbol
Limit Speed
(km/h)
80
94
670
130
95
690
140
96
710
150
97
730
160
98
750
170
99
775
180
100
800
190
101
825
200
102
850
210
103
875
240
104
900
Above 240
105
925
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Life
Index
Load (Standard Ratei 100)
WHEELS & TIRE

STAVIC - 2004.09
4H
2. SPECIFICATION
Description
Wheel
Tire
Specification
Size
Aluminum type
Wheel nut tightening torque
Aluminum wheel
Type
Radial tire
Inflation pressure (psi)

Wheel alignment
Toe-in
Camber
6.5J x 16
13 ~ 16 kgf.m
Radial Tire
P225/65R16
35 psi
Front
0 ~ 4 mm
Rear
0.4 0.08 (5 mm 1 mm)
Front
0 30' (0 0.5)
Rear
-1 30' (-1 0.5)
Caster
4.5 30'
3. TIRES ABNORMAL PHENOMENA

Standing Wave
Hydroplaning
High speed
driving
During running the rotating tire repeats deformation and

restoring movement generated in tread. But when the wheel
rotating speed reaches high, the next deformation applied
to tire before restoring last deformation so the trembling
wave appears in the tread portion. The lower the tire pressure the severe the trembling wave appears during the high
speed.
WHEELS & TIRE

STAVIC - 2004.09
Low speed
driving
The condition of driving a vehicle fast on the road surface

covered with water can cause tires to fail to rotate with a
good contact on the surface, so results in remaining them
a float. This is so-called hydroplaning. It causes brake
failure, lower tractive force and losing the steering performance so it is very vulnerable condition.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H
4. WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component must
be strong enough to with stand and absorb extreme punishment. Both the steering system and the front and the rear
suspension must function geometrically with the body
mass.
Camber
Tire centerline
Perpendicularline
Perpendicularline
Tire centerline
The steering and suspension systems require that the front

wheels self-return and that the tire rolling effort and the
road friction be held to a negligible force in order to allow
the customer to direct the vehicle with the least effort and
the most comfort.
A complete wheel alignment check should include measurements of the rear toe and camber.
Toe-in
Camver (+)
Camver 0
Camver (-)
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the tires
tilt outward, the camber is positive. When the tires tilt
inward, the camber is negative. The camber angle is measured in degrees from the vertical. Camber influnces both
directional control and tire wear.
Front side
If the vehicle has too much positive camber, the outside

shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is measured in degrees and is not adjustable.
Toe-in is the turning in of the tires, while toe-out is the

turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the wheel
support system which occur when the vehicle is rolling
forward.
The specified toe angle is the setting which achieves-degrees 0 of toe when the vehicle is moving.
Incorrect toe-in or toe-out will cause tire wear and reduced
fuel economy. As the individual steering and suspension
components wear from vehicle mileage, additional toe will
be needed to compensate for the wear. Always correct
the toe dimension last.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
WHEELS & TIRE

STAVIC - 2004.09
4H
Caster
Front side
Center line
Steering
axle
Center line
Steering
axle
Caster (+)
Caster 0
Caster (-)
Caster is the tilting of the uppermost point of the steering

axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is positive and a forward tilt negative. Caster influences directional control of the steering but does not affect tire wear.
Weak springs or overloading a vehicle will affect caster.
One wheel with more positive caster will pull toward the
center of the car. This condition will cause the car to move
or lean toward the side with the least amount of positive
caster. Caster is measures in degrees and is not
adjustable.
WHEELS & TIRE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4H

Tire
1. Remove the wheel cap.
2. Support the vehicle with safety jack.

Loosen the wheel nuts and raise the vehicle carefully.
3. Remove the wheel nuts.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
WHEELS & TIRE

STAVIC - 2004.09
4H

[Notice]
Clean the mating surface of wheel and hub. Do not apply
grease or oil to bolts and nut. It may cause the looseness of
the fasteners.
Lift up the vehicle until the tire is off approx. 3 mm from
ground.
Tighten the wheel nuts by the order as shown in the figure
with several steps.
Tightening torque
WHEELS & TIRE

STAVIC - 2004.09
Aluminum wheel: 120 ~ 130 Nm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
10
4H
Spare Tire
1. Prepare the spare tire handle and wheel nut wrench.
2. Install the handle through the hole at the rear side of the
vehicle.
3. Connect the wheel nut wrench at the end of the handle.
4. Turn the wheel nut wrench counterclockwise until the wire is loosened.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
WHEELS & TIRE

STAVIC - 2004.09
4H
11
5. Pull out the lift plate from spare tire.

6. Put the lift plate into the center of the wheel when
installing.
7. Turn the handle clockwise until it sounds click.
8. Remove the handle and the wheel nut wrench.
[Notice]
Always keep the spare tire available.
When reinstalling the spare tire, securely fasten it.
If the lift plate is not in the center position or the spare tire
is not securely fastened, the spare tire may be out of position
during driving.
If a movement of spare tire is found, check the system and
reinstall in needed.
The wheel nut tightening surface of the spare tire should
be faced toward ground.
This device is desined only for manual operation. Never
use the impact type tool to remove the spare tire.
Store the flat and damaged tire in the trunk.
WHEELS & TIRE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
4H
6. MAINTENANCE AND REPLACEMENT

Separation
1. Fix the tire into the equipment and pull out the valve core
from the tire. Discharge the air inside the tire completely.
[Notice]
The assembly and disassembly of the tire is dangerous
working job. So, only the skillful worker must work this job
following the approved procedures.
2. Tighten the locker in the center of the equipment to

assemble the rim to the equipment.
3. Remove the balance weight on the rim.
4. Separate the tires bead from the rim flange using the
approved lubricant.
[Notice]
Do not use silicone, synthetic detergent and gasoline, etc.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
WHEELS & TIRE

STAVIC - 2004.09
4H
13
5. Apply the lubricant between the rim and the bead.
6. Insert the removal lever between the tires bead and the
rim and separate the rim from the tire.
[Notice]
Do not use the tool that may cause any damage such as pipe,
damaged bar.
7. Pull out the opposite bead upward using the lever and
then separate the bead from the rim.
Maintenance
1. Check any damage the rim and replace as needed.
[Notice]
Do not repair the rim as welding or soldering.
Replace the new valve as replaces new tire.
WHEELS & TIRE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
4H
Installation
1. Clean the rust, damaged rubber and dust, etc on the
rims surface with the brush.
2. Install the rim to the equipment with the valve upward.

3. Tighten the locker in the center of the equipment to
assemble the rim to the equipment.
4. Apply the lubricant at the both bead portions and both

rims flange of the tire.
5. Check any foreign material or liquid for the tire inside

and then install to push down the tire.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
WHEELS & TIRE

STAVIC - 2004.09
4H
15
6. Set the tire pressure to the specifications.

[Notice]
Do not remove the tire from the equipment before setting the
tire pressure.
Specification of the
tire pressure
WHEELS & TIRE

STAVIC - 2004.09
30 psi (2.1 kgcm2)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
4H
7. INSPECTION
Visual Inspection
Condition
Rapid wear at
Cause
Under inflation or lack of rotation
Action
Adjust inflation pressure
shoulders
Rapid wear at center
Over inflation or rotation
Tread damage
Low the inflation pressure
Uneven wear
Incorrect camber
Adjust camber
Incorrect toe-in
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
WHEELS & TIRE

STAVIC - 2004.09
4H
17
Condition
Cause
Action
Feathered edge
Incorrect toe-in
Adjust toe-in
Bold spot
Unbalanced wheel
Adjust wheel balance
Sharply wear at the tread outside
Unbalanced wheel
Adjust
Wheel bearing play
Check play
Check pre-load
WHEELS & TIRE

STAVIC - 2004.09
Ball joint play
Check
Check
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4H
General Inspection
Tread
Inspect the tread condition on the tire surface and various
damages resulting from the foreign material, crack, stone or
nail etc. If there is any damage in the tire, repair or replace it.
Tire Wear
Measure the depth of the tire tread. If the depth of the tread
is below the specified value, replace the tire.
Limit of the Tread Wear
1.6 mm
You can see the mark in the groove, this is the indicator
of the tread wear limit.
The limit of the tread wear for all season tires are 1.6 mm
as same as the general tires and the platform mark
indicates as .
Tire Inflation Pressure

1. Inflation pressure
Front / Rear
35 psi
2. Inspect the pressure of the tire surface and check the

inflation pressure.
[Notice]
Lower than recommended pressure can cause tire squeal
on turns, hard steering, tire cord breakage and tire rim
bruises, etc.
Higher than recommended pressure can cause hard ride,
tire bruising or damage and rapid tread wear at the center
of the tire.
Sufficient
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Insufficient
Excessive
WHEELS & TIRE

STAVIC - 2004.09
4H
19
Wheel Runout
Measure wheel runout with an accurate dial indicator. Measurement may be taken with the wheels either on or off the
vehicle, using an accurate mounting surface such as a wheel
balancer. Measurements may be taken with or without the
tire mounted on the wheel.
1. Measure the dial runout and lateral runout on both the
inboard and outboard rim flanges.
Specification
2.66 mm
2. Measure free radial runout on the tire tread.

Specification
2.03 mm
[Notice]
If any measurement exceeds the above specifications, replace
the applicable tires or wheels.
Wheel Balance
Balance is the easiest procedure to perform and should be
done first if the vibration occurs at high speeds or if the tires or
the wheels are replaced.
When proceeding the wheel balancing procedure refer to the
following;
1. Do not the wheel weight over two at the inboard and the
outboard flanges.
2. The total weight ofthe wheel weight should not exceed
the 150 g (3.5 ounces)
3. Balancing the assemblies with the factory aluminum
wheels requires the use of the special nylon-coated, clipon wheel weights.
Weight point
Balance weight
Balance weight
10 g
20 g
30 g
40 g
50 g
60 g
0.4 oz
0.7 oz
1.10 oz
1.40 oz
1.80 oz
2.10 oz
Balance weight
Weight point
WHEELS & TIRE

STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
4H
Rotation of Tires
Front and rear tires perform different jobs and can wear differently depending on the tires of road driven, driving condition,
etc.
The front tires will wear faster than the rear ones. To avoid
uneven wear of tires and to prolong tire life, inspect and rotate
the tires every 5,000 km (3,100 miles). After rotating the tires,
adjust the tire inflation pressures and be sure to check wheel
nuts tightness.
[Notice]
Do not mix different types of tires on the same vehicle such as
radial, bias and bias-belted tires except in emergencies,
because vehicle handling may be seriously affected and may
result in loss of control.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
WHEELS & TIRE

STAVIC - 2004.09
4H
21
Condition
Irregular tire wear
Driving noise, vibration
Cause
Improper tire inflation pressure
Adjust
Poor wheel balance
Adjust
Improper tire rotation
Rotation tires on the

maintenance schedule
Poor toe-in
Adjust
Poor adjusting the pre-load of the wheel bearing
Adjust
Poor braking performance
Adjust
Low tire inflation pressure
Adjust
Poor balance of wheels, tires
Adjust
Severe vibration due to wheels, tires

Irregular tires wear
Rapid wear
STAVIC - 2004.09
Adjust or replacement
Check and adjust
Excessive tire inflation pressure
Adjust
High speed driving with low tire pressure
Adjust
Excessive vehicle weight
WHEELS & TIRE
Action
Proper weight
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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4I
The propeller shaft transfers the power through the transmission and transfer case to the front/rear axle differential carrier
(final reduction gear). It is manufactured by a thin rounded
steel pipe to have the strong resisting force against the torsion
and bending.
Both ends of propeller shaft are connected to the spider and
the center of propeller shaft is connected to the spline to accommodate the changes of the height and length. The rubber
bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration.
Specification
Description
Specification
Structure
Yoke and spider type universal joint
Joint type
Spider (Needle roller bearing)
Number of spiders
Front
TOD T/C
Rear
Outer diameter of spider (mm)
17.893
Tube run-out (after installation)
below 0.4 mm
Below 14.5 g.cm @ 4500 rpm (Front shaft + Full time T/C)
Unbalance
Below 18.0 g.cm @ 4500 rpm (Rear shaft + Full time T/C)
Front shaft dimension
M/T(A/T) + 4426 TC (TOD)
495.8 (center position) x 50.8 (3.05t)
Length x Outer diameter (mm)

Rear shaft dimension
Length x Outer diameter (mm)
DI engine + M/T(A/T) + 4426 TC (TOD)
606.1 (compressed) x 72.2(2t)

+ 769.5 x 76.2 (2t)
DI engine + M/T + 2WD
923.5 x 63.5 (2t)

+ 750.4(compressed) x 63.5 (2t)
DI engine + A/T + 2WD

+ 769.5 x 63.5 (2t)
Gasoline + M/T + 2WD
923.5 x 76.2(2t)
+ 750.4 (compressed) x 63.5 (2t)
Gasoline + A/T + 2WD

+ 769.5 x 63.5 (2t)
PROPELLER SHAFT
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4I
2. COMPONENTS AND LOCATION

Front Prepeller Shaft Assembly
Bolt
Bolt
CV joint
Front propeller shaft assembly
Universial joint
Rear Prepeller Shaft Assembly
1st rear propeller shaft
CV joint
2nd rear propeller shaft
Universial joint
Bolt/washer/nut
Center bearing assembly
Universial joint
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Bolt
PROPELLER SHAFT
STAVIC - 2004.09
4I

Removal
Front Propeller Shaft (4WD)
1. Unscrew propeller shaft mounting bolts and remove the shaft from the vehicle. (T/C : 17 mm - 4EA, Axle : 14 mm
- 4EA)
* Leave a guide mark before

disassembly, and refer to
the mark when reinstall
PROPELLER SHAFT
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4I
Rear Propeller Shaft

1. Unscrew propeller shaft mounting bolts. (T/C : 17 mm 4EA, Axle : 14 mm - 4EA)
Center bearing
Axle side
T/C side
2. Unscrew the rear propeller shaft center bearing

mounting bolts (17 mm - 2 EA)
* Leave a guide mark
before disassembly,
and refer to the mark
when reinstall.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
PROPELLER SHAFT
STAVIC - 2004.09
4I
Installation
1. Installation in the reverse order of removal.
2. Keep the tigtening torque.
3. Keep the guide mark when install.
4. Check and replace parts if defective.
(1) Rear propeller shaft (T/C)
(2) Center bearing bracket
3. Rear axle
(3) Rear propeller shaft (Axle)

1. Rear - T/C
4. Front axle
2. Center bearing
5. Front - T/C
(4) Front propeller shaft (Axle)

PROPELLER SHAFT
STAVIC - 2004.09
(5) Front propeller shaft (T/C)

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
4I
4. INSPECTION
Disassembly
1. Place an alignment mark and remove the propeller shaft.
2. Place an alignment on the spiders before removing.
3. Remove the snap ring with snap ring pliers.
4. Tap the yoke shoulder on shaft with copper hammer to

remove the roller bearing. Remove the other bearings with
same manner.
5. If it cannot be removed, hold the welding area with vise
and remove the needle bearing by using a suitable drift
and hammer.
6. Disassemble the universal joint.

The universal joint compensates the angle changes due
to vertical movement of the axle shaft.
7. Remove the intermediate bearing bracket and remove

the bearing with special tool.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
PROPELLER SHAFT
STAVIC - 2004.09
4I
Inspection
1. Visual Check
Check the components for wear and crack and replace if
needed.
2. Outer diameter of spider journal
Specified value
17.893 mm
Limit
17.910 mm
3. Clearance between spider journal and bearing

Specified value
0.03 ~ 0.098 mm
Limit
0.25 mm
4. Run-out of propeller shaft

Set up the dial gauge on the center point of propeller
shaft and measure the run-out. If the run-out is out of the
specified range, correct it with press or replace it with
new one.
Limit
0.4 mm
5. Starting torque of universal joint

Specified value
3 ~ 8 kg.cm
6. Major causes of vibration
Balance weights missing

Excessive run-out of propeller shaft
When using the general bolts
Excessive wear of universal joint
Stuck in sleeve joint
Vibration is mainly caused by the angle changes in
front and rear universal joint. It normally occurs when
the vehicle speed is 60 ~ 100 km/h.
PROPELLER SHAFT
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
10
4I
Assembly
Clean the components and replace if damaged.
Flange yoke
1. Align the alignment marks on the yoke and assemble

the spider, bearing and snap ring.
Spider
Bearing
Yoke
Snap ring
2. Apply the grease to the inner lip of needle roller bearing

and assemble the needle roller.
3. Install the yoke bearing shaft on the shaft and insert the
spider. Place the cap on the opposite side and tap it
with plastic hammer to seat it. Adjust the clearance of
spider below 0.1 mm and install the snap ring.
Needle roller bearing
Grease
4. Apply the specified grease on the propeller shaft and

install it.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
PROPELLER SHAFT
STAVIC - 2004.09
4I
11
Symptom
Vibration
Noise
Cause
Poor installation of sliding joint
Adjust
Bending of propeller shaft
replace
Incorrect symmetry of universal joint snap rings
Adjust
Loose yoke bolt
Tighten
Worn or damaged universal joint bearing
Replace
Missing universal joint snap ring
STAVIC - 2004.09
Adjust and replace
Loose yoke connection
Tighten
Worn sliding joint spline
Replace
Lack of grease
PROPELLER SHAFT
Action
Add
CHANGED BY
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AFFECTED VIN
12
4I

116 589 09 43 00 (P 99 48 003 0A)
Application
Centering the clutch disc
Remover and installer
129 589 00 34 00 (P 99 33 002 0B)
Removal of bearing
Pulling arms
CHANGED BY
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AFFECTED VIN
PROPELLER SHAFT
STAVIC - 2004.09
4J
BRAKE SYSTEM
Brake System
Brake Pedal
Even though a driver cuts off the power, while driving, the
vehicle continues to move due to the law of inertia.
Therefore, a braking device is needed to stop the vehicle.
The brake system normally uses the frictional discs that
converts the kinetic energy to the thermal energy by frictional operation.
The brake system consists of the brake disc (front wheel),
brake disc or drum (rear wheel), parking brake (mechanical
type), master cylinder, booster, pedal and supply lines
(pipes and hoses).
Hydraulic Brake
Brake pedal uses the leverage effect to apply bigger force
to the brake master cylinder.
Master Cylinder
This system uses the leverage effect and Pascals

principle. When depressing the brake pedal, the pedal
pressure is increased by booster and is delivered to master cylinder to generate hydraulic pressure.
The hydraulic pressure generated by the master cylinder
is delivered to the brake caliper through the brake pipes or
hoses.
This hydraulic pressure pushes the brake calipers, accordingly the caliper pads are contacted to brake disc to
generate the braking force.
BRAKE - GENERAL
STAVIC - 2004.09
Rear
Front
The brake master cylinder is designed to convert the force

from the brake master cylinder to the high hydraulic
pressure. The brake system uses the tandem type master cylinder with in-line 2 pistons.
The in-line 2 pistons generate the hydraulic pressure. The
piston cup on the piston keeps the sealing conditions in
cylinder and prevents the oil leaks. The hydraulic pressure generated by the primary piston is delivered to the
front wheels, and the hydraulic pressure generated by the
secondary piston is delivered to the rear wheels.
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4J
Brake Booster
The brake booster is a power assist device for brake
system. It relieves the pedal depressing force by using
the pressure difference between the vacuum pressure generated by vacuum pump in intake manifold and the atmospheric pressure.
1. Pressure distribution at working
2. Pressure distribution after working
Vacuum pump
When depressing the brake pedal, the push rod (1) in

booster pushes the poppet (2) and valve plunger (3). The
poppet (2) pushes the power piston seat (5) resulting in
closing the vacuum valve (9). The chamber (A) and (B) in
power cylinder are isolated and the valve plunger (3) is
separated from the poppet (2). And then the air valve (6)
opens and air flows into the chamber (B) through filter.
Then, the power piston (5) pushes the master cylinder
push rod (7) to assist the brake operation.
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When releasing the brake pedal, the valve plunger (3) returns back to the original position by return spring (4) and
the air valve (6) closes. At this time, the vacuum valve (9)
opens and the pressure difference between chamber (A)
and (B) in power cylinder is eliminated. Accordingly, the
power piston (5) returns back to original position by the
reaction of master cylinder (10) and the diaphragm return
spring (8).
BRAKE - GENERAL
STAVIC - 2004.09
4J
2. SPECIFICATION
Item
Type & Specification
Front brake type
Ventilated disk
Rear brake type
Solid disk
Master cylinder type
Booster type
Brake fluid capacity, type, replacement period
Brake pipe & hose replacement period
Brake pad, shoe, disk
BRAKE - GENERAL
STAVIC - 2004.09
Tendem type
Tendem booster (Foot control)
0.6 (Liter), DOT4, by every 2 years
Every 20,000 km or 12 months and change if needed
Checking by every 10,000 km
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AFFECTED VIN
4J
3. COMPONENTS
Return spring
Vacuum pump
Pedal bracket
Vacuum
hose
Booster
Booster
Gasket
Brake pedal
Switch - Stop lamp
O-ring
Reservoir tank
Pad
Pressure sensor
Cable - RR
speed sensor
Pad
M/T
A/T
Cable - FRT
speed sensor
Brake dust shield
Knuckle
Brake dust shield
Hub flange
Knuckle
Hub flange
Brake disk
Brake disk
Steering
knuckle assy
CHANGED BY
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AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
Release lever
Parking brake assy
HECU
Cable
Brkt - HECU
Parking brake cable

- rear RH
Damper
Parking brake cable

- rear LH
Pad
Tension spring
Equalizer
Brake shoe
Adjuster
Return spring - Upper
Return spring - Lower
Knuckle
Operating lever
Brake dust shield
Hub flange
Brake disk
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
4J
4. MASTER CYLINDER & BOOSTER

ABS system is basically equipped to STAVIC.
Vehicle which adapted ESP system in option has two pressure sensors under master cylinder and these two sensor are
used for BAS (Brake Assist System) system.
Vehicle with ESP
Vehicle with ABS
Vacuum Pump
Booster
Vacuum hose
Gasket
O-ring
Brake fluid
reservoir
tank
Pressure
sensor
Master
cylinder
<Vehicle with ESP>
Brake fluid reservoir tank
Master cylinder
[Notice]
Do not disassemble the brake oil pressure sensors These can not be reinstalled of disassembled.
After reinstall the reserver tank perform a air bleeding of brake system
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AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
5. INSPECTION
Air Bleeding (With ABS)
6. Repeat the step 4 through 5 until clear brake fluid
comes out of air bleed screw.
7. Perform the same procedures at each wheel.
[Notice]
Repeat the step 4 through 5 until clear brake fluid comes
out of air bleed screw.
After bleeding the air, make sure that the brake system is
properly operated.
[Notice]
Replace the brake oil at every 2 years.
[Notice]
Bleed air in the following order:
Right rear brake Left rear brake Right front brake
Left front brake
Check the fluid level repeatedly during air bleeding, and
add fluid if needed.
1. Apply the parking brake and start the engine when

the shift lever is at P position.
2. Connect the oil supply device (air bleeding device)
with air compressor to brake reservoir. The oil supply
device should be filled with sufficient oil.
3. Loosen the air bleed screw in caliper and place an
empty container under the screw.
4. Bleed the air in each wheel by using diagnostic device
(Scanner). At this time, the modulator motor runs for
180 seconds.
5. Simultaneously, run the oil supply device to supply
oil and depress the brake pedal repeatedly.
This procedure needs at least 3 persons for doing
below jobs:
1. Collect the bleeding oil into the container.
2. Depress the brake pedal repeatedly.
3. Check the conditions of oil supply device.
[Notice]
8. Always start to bleed the air at the farthest wheel

from the brake master cylinder. Observe the sequence
number as shown in the above figure.
[Notice]
Always bleed the air after replacing the brake fluid or
master cylinder, caliper, brake hose and pipe.
Never reuse the used brake fluid.
Do not pump the brake pedal too fast. It may cause
some troubles for air bleeding operation.
Be careful not to splash the brake fluid on painted
area or body.
Check the connection areas for leaks after air bleeding.
Keep the brake pedal depressing until the bleed screw is

fully tightened.
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
10
4J
After Replacing Master Cylinder

1. Add oil after replacing the master cylinder.
2. Pump the brake pedal several times until the hydraulic
pressure is generated. Then, keep the pedal depressing.
3. Loosen the pipe screw at the outlet port in master cylinder
to bleed the air.
4. Repeat step 3 until clear brake fluid comes out of air
bleed screw.
5. If the hydraulic pressure is not properly generated during
pumping the brake pedal, bleed the at the outlet pipe in
hydraulic unit and wheel.
After Replacing Hydraulic Unit

1. Add oil after replacing the hydraulic unit.
2. Pump the brake pedal several times until the hydraulic
pressure is generated. Then, keep the pedal depressing.
3. Loosen the pipe screw at the outlet port in hydraulic unit
to bleed the air.
4. Repeat step 3 until clear brake fluid comes out of air
bleed screw.
5. If the hydraulic pressure is not properly generated during
pumping the brake pedal, bleed the at the wheel.
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AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
11

Vacuum Hose - Brake Booster
1. Disconnect vacuum hose (A) from brake booster.

2. Remove vacuum hose mounting nut (B).
3. Disconnect vacuum hose (C - Vacuum modulator side).
4. Disconnect vacuum hose & bracket (D)
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
12
4J
Brake Fluid Reservoir Tank

1. Open the tank cap and drain the brake oil.
2. Disassemble brake fluid reservoir from master cylinder.
[Notice]
Do not apply excessive force to remore the reservoir.

[Notice]
Use only specified brake fluid.
After replacing the brake fluid reservoir be followed airbreeding job moust.
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AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
13
Master Cylinder (ESP Equipped Vehicle)

Preceding work : Drain the brake fluid
1. Disconnect the brake fluid level switch connector (A).
2. Disconnect brake pipes (B, C) from master cylinder.
3. Remove master cylinder with master cylinder mounting

nuts.
[Notice]
Be careful not to splash the brake fluid onto painted body. If
splashed, immediately clean the contaminated area.

5. Do the air bleeding job.
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
14
4J
Brake Booster
Preceding work : Drain the brake fluid
1. Disassembly the master cylinder assembly and remove
clevis pin on the booster push rod.
2. Remove the booster mounting nuts.

3. Disassemble the brake booster from vehicle.

[Notice]
Air-bleeding job must be done after repairing.
CHANGED BY
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AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
15
Stop Lamp Switch

2. Disconnect the stop lamp switch connector.
3. Unscrew the lamp switch mounting nut and disassemble
the switch.
Tightening torque
21 ~ 35 Nm
4. Install in the reverse of removal.
Stop Lamp Switch Check

1. Check if the electrical circuit is closed when the switch
plunger is pushed.
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
16
4J
Brake Pedal
1. Remove two stop lamp switch bracket bolts.
Tightening torque
18 ~ 22 Nm
2. Remove brake pedal bracket bolts.

Tightening torque
18 ~ 22 Nm
3. Disassemble the brake pedal assembly.

Nut
Pad
Stopper
Return spring
Washer
Brake pedal
Bolt
Bracket

Tightening torque
16 ~ 32 Nm
5. After installation, hit the brake to check if its operation is

correct.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
17
Brake Pedal Check

Pedal Height / Maximum Stroke
Check the brake pedal with below procedures:
1. Start the engine.
2. Depress the brake pedal around 3 times.
3. Depress the brake pedal with approx. 30 kg and measure
the distance (A) between the upper surface of pedal pad
and the lower dash panel.
4. If the measured value is below the specified value, check
the following causes:
Pad wear, Shoe wear, Air in brake system, Defective
automatic clearance adjuster of rear brake shoe.
5. If the measured value is out of the specified range, adjust
the length of push rod by using lock nut in the brake
booster push rod.
Pedal height
Specified value (A)
177 mm (from carpet surface)
Operating
rod
Stop lamp
switch
[Notice]
If the value is out of the specified range, adjust the pedal
height by using lock nut of stop lamp switch.
Operating rod
lock nut
Stop lamp
switch lock nut
Maximum stroke
Specified value (C)
138 mm
[Notice]
If the value is out of the specified range, adjust the maximum
stroke by using stop lamp and lock nut.
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
4J
Pedal Free Play

Depress the brake pedal several times to discharge the vacuum
pressure of the power booster. Measure the pedal free play
while pressing the brake pedal by hand.
Specified value
3 ~ 8 mm
If the free play is below the specified value, check if the clearance between the outer case of the stop lamp and the brake
pedal is within the specified range.
If the clearance is out of the specified range, the clearance
between the clevis pin and the brake pedal arm is too large.
Check the components and repair if needed.
Brake Booster Check
Normal
1. Let the engine run for 1 ~ 2 minutes and stop it. If the
brake pedal stroke is shortened as pumping the brake
pedal, the system is normal. If not, the system is
defective.
Faulty
2. Depress the brake pedal several times with engine off. If

the brake goes down when starting engine with pedal
depressed, the system is normal. If not, the system is
defective.
3. Depress the brake pedal when the engine is running. If
the pedal height is not changed when stop the engine,
the system is normal. If not, the system is defective.
If the above 3 conditions are not satisfied, check the parts
concerned such as valve, vacuum hose, booster, etc.
Engine stop
Engine running
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
19
Symptom
Noise or vehicle vibration when applied
Cause
Incorrectly mounted back plate or caliper
Loosened bolt of back plate or caliper
Crack or uneven wear of brake drum or disc
Retighten
Replace
Clean
Pad or lining sticking to contact surface
Replace
Excessive clearance between caliper and pad
Repair
Uneven contact of pad
Repair
Loosened suspension
Poor braking
Repair
Foreign material inside the brake drum
Lack of lubrication
Pulls to one side when
braking
Action
Lubrication
Retighten
Incorrect tire pressure between left and right
Adjust
Poor contact of pad or lining
Repair
Oil or grease is applied to pad or lining
Replace
Bent or uneven wear of drum
Replace
Incorrectly mounted wheel cylinder
Repair
Faulty auto adjuster
Repair
Dirty or lack of fluid
Replenish or replace
Air in brake system
Bleeding
Faulty brake booster
Repair
Poor contact of pad or lining
Repair
Oil or grease on pad
Replace
Repair
Over heated rotor due to dragging pad or lining
Repair
Clogging brake line
Repair
Faulty proportioning valve
Repair
Increasing pedal stroke
Air in brake system
(Pedal goes to floor)
Fluid leaking
Repair
Excessive clearance between push rod and m/cylinder
Adjust
Parking brake is not fully released
Repair
Incorrect adjustment of parking brake
Adjust
Brake dragging
Weak return spring of brake pedal

Incorrect pedal free-play
Broken rear drum brake shoe return spring
Lack of lubrication
Poor parking brake
Repair
Replace
Lubrication
Replace
Insufficient clearance between push rod and master cylinder
Adjust
Worn brake lining
Replace
Dirty brake lining surface by grease or oil
Replace
Binding parking brake cable
Replace
Excessive lever stroke
STAVIC - 2004.09
Replace
Damaged master cylinder check valve or piston return spring
BRAKE - GENERAL
Bleeding
Repair
Adjust lever travel or
check the cable
CHANGED BY
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AFFECTED VIN
20
4J
FRONT BRAKE
Caliper
Adjustment of Clearance
The disc brake is normally used for front wheels, however,

currently it is also used for rear wheels. The floating caliper type disc brake installed in this vehicle has only one
brake cylinder at one side of caliper. The hydraulic pressure generated by master cylinder pushes the piston to
contact the pad against the disc. The caliper is moved to
contact to the opposite pad.
When the hydraulic pressure is applied to the piston, the

piston moves to push the pad. The piston seal, which extent considerable pressure against the piston, moves with
cylinder.
The brake disc features:
When the pressure is released from the piston, the piston

comes back to its original position by a restoring and elastic
force of the seal.
*
*
*
*
Excellent radiation due to it is exposed to ambient air

Less braking force changes
No uneven braking
Simple structure and operation
However, the piston seal shape is deformed since the piston seal is fixed at the cylinder groove as shown in below
figure.
When the pad wear is excessive, the piston seal cannot

reach to the desired point because the seals deformation
is limited.
Accordingly, the piston always comes back by the deformed distance of piston seal, it keeps the initial clearance.
Piston
Pad
Disc
* General description
1. Piston
3. Pad
2. Piston seal
a. Clearance
Specifications
Item
Specification
Type
Ventilated disc type
Inner diameter of caliper cylinder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
42.9 x 2 mm
Pad thickness
10.5 mm
Disc thickness
26 mm
BRAKE - GENERAL
STAVIC - 2004.09
4J
21
2. COMPONENTS
For strong and safe brake force, ventilated disk and double piston type is adapted to front brakes.
Brake disk
Caliper
Brake hose
Disk
Caliper carrier
Pad spring
Brake pad
Bolt - Caliper
Piston
Brake
BRAKE - GENERAL
STAVIC - 2004.09
Caliper assembly
CHANGED BY
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AFFECTED VIN
22
4J

Caliper / Brake Disk
Preceding work : Remove the tire
[Notice]
1. Disconnect brake hose from caliper.
Tightening torque
20 ~ 30 Nm
Be careful not to splash the brake oil onto the painted

body.
2. Unscrew two caliper mounting bolts and disassemble the caliper assembly.
Tightening torque
85 ~ 105 Nm
3. Unscrew two nuts and disassemble the brake disk.

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
23
Brake Pad Change

1. Unscrew brake.
Tightening torque
22 ~ 34 Nm
2. Swing up the callper cylinder assembly and hold it not

to damage the hose.
3. Remove the brake pads and replace them with new ones.
4. Compress the brake piston with special tool.

[Notice]
Insert the used pad to compress brake piston.
5. Install the caliper assembly.
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
24
4J
Inspection
Clean the dissembled components and visually check the
followings:
Wear, rust and damage on the cylinder and piston
Damage, crack and wear on cylinder body and guide pin
Uneven wear and oil contamination on boot
Damage and tear on boot
Scratch and bending on disc plate
Pad Thickness
1. Remove the tire.
2. Measure the pad thickness and replace it if it is below
the wear limit.
New pad thickness
Wear limit
10.5 mm
2 mm
Brake Disc Thickness

1. Measure the disc thickness at over four points.
2. If any of measured points is below the wear limit, replace
the brake disc with new one.
New pad thickness
Wear limit
28 mm
25.4 mm
Brake Disc Run-out

1. Install the dial gauge on the side of brake disc and
measure the run-out while rotating the brake disc.
2. If the measured value exceeds the limit, replace the brake
disc with new one. Otherwise, it may cause the pedal
vibration and shimmy when braking.
0.03 mm (before installation)
Limit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
0.07 mm (when installed)
BRAKE - GENERAL
STAVIC - 2004.09
4J
25

661 589 16 33 00 (W 99 48 002 0A)
Front ABS tooth wheel puller
661 589 17 33 00 (W 99 48 003 0A)
Application
Removal of ABS front brake
tooth wheel
Front ABS tooth wheel installer
Installation of ABS front brake

tooth wheel
Piston Puller
Compression of caliper piston
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
32
4J
PARKING BRAKE
1. COMPONENTS
Pedal assembly
Equalizer assembly
Return spring - upper

Adjusting bolt
Shoe holding spring
Return spring - lower
Operating lever
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
33
Release lever
Release cable
Brake damper
Pedal assembly
Pedal
Equalizer assembly
Equalizer bolt
Tension spring
Rear brake cable - LH
Rear brake cable - RH
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
4J

Pedal Assembly
Preceding work : Remove lower cover - crash pad
1. Release the equalizer bolt.
[Notice]
Replace bolt when reinstall.
2. Remove the clamping ring from pedal assembly and disconnect the brake cable (1).
3. Disconnect the parking brake switch (2).
CHANGED BY
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AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
35
4. Remove pedal assembly mounting bolts (12 mm) & nuts (12 mm).
Tightening torque
10 ~ 14 Nm
Nut
Bolt
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
36
4J
Equalizer Assembly
1. Remove the equalizer adjustment bolt (1).

2. Unscrew the mounting bolt (2) in equalizer lever and disconnect front brake cable (3).
3. Disassemble equalizer lever (4) from frame floor mounting.
4. Disconnect rear brake cable (5) and disassemble the equalizer.
Adjustment
1. Park the vehicle on the car lift and set blocks under front
tires.
2. Place the shift lever to N (A/T) or Neutral (M/T).
3. Release the parking brake.
4. Lift the rear wheels with supplementary lift.
5. Check the brake force as rotating the wheels - specified
hand brake notch : 5
6. If the brake force is not made enough, adjust the parking
brake adjust nut in the brake drum.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4J
37
Parking Brake Shoe

Components
Return spring - upper
Adjusting bolt
Shoe holding spring
Return spring - lower
Operating lever

1. Remove shoe holding spring (2 EA) with plier.
2. Remove upper return spring & adjust bolt.
BRAKE - GENERAL
STAVIC - 2004.09
CHANGED BY
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AFFECTED VIN
38
4J
3. Remove lower return spring and disassemble sperating lever from brake cable.
Adjustment
1. Have the brake shoe contact the inner face of brake disk by winding the brake adjust bolt using a tool (screw
driver), and then, unscrew the bolt by 4 ~ 5 notch. (Clearance between brake disk and brake shoe : 0.2 mm)
2. Check if the wheel become locked when brake force is applied.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BRAKE - GENERAL
STAVIC - 2004.09
4K
ABS SYSTEM
The aim of the ABS is to mmaintain steerability and driving stability and to take the burden off the driver. If the stopping
distance is shorter on some road surfaces (carriageway conditions), this is a gift of physics and not a development aim.
ABS is a device which senses that one or more of the wheels are locking up during braking. It monitors the rotational
speeds of the wheels and reduces hydraulic pressure to any wheel it senses locking up. It is controlled by both
mechanical and electronic components. When you apply the brakes, the ABS will regulate the flow of brake fluid being
delivered to the brake calipers. By the use of electronic computers, the brakes rapidly alternate (at a rate of 30 times per
second) from full pressure to full release.
DRIVING PHYSICS
To give you a better understanding of the tasks and functions of ABS, we will first look at the physics principles.
The Stopping Distance

The stopping distance depends on the vehicle weight and initial speed when braking starts. This also applies for vehicle
with ABS, where ABS always tries to set an optimum brake force on each wheel. As great forces are exerted between
the tires and the carriageway when braking, even with ABS the wheels may scream and rubber is left on the road. With
an ABS skid mark one may be able to clearly recognize the tire profile. The skid mark of an ABS vehicle does not
however leave any hint of the speed of the vehicle in the case of an accident, as it can only be clearly drawn at the start
of braking.
Brake Force on a Wheel

The maximum possible brake force on a wheel depends on the wheel load and the adhesion coefficient between tire and
carriageway. With a low adhesion coefficient the brake force, which can be obtained is very low. You are bound to know
the result already from driving on winter roads. With a high adhesion coefficient on a dry road, the brake force, which can
be obtained, is considerably higher. The brake force, which can be obtained, can be calculated from below formula:
Maximum brake force

FBmax = Vehicle Weight x Adhesion coefficientmh
The braking process cannot be described sufficiently accurately with the brake forces calculated. The values calculated
only apply if the wheel is not locked. In the case of a locking
wheel, the static friction turns into lower sliding friction, with
the result that the stopping distance is increased. This loss of
friction is termed slip in specialist literature.
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STAVIC - 2004.09
Brake force on a wheel
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Slip
The brake slip is the difference between the vehicle speed and the wheel circumference speed. If the wheel locks, the
slip is greatest, that is 100 %. If the wheel is running freely and unbraked, the slip is the lowest, equal to 0 %. Slip can
be calculated from the vehicle speed Vveh and the wheel speed Vw. The equation for this is:
S=
Vveh - Vw
Vveh
X 100 %
Vveh = 100 km/h, Vw = 70 km/h

S=
100 - 70
100
X 100 %
The slip is 30 %.
Kamm circle
Before we go into the Kamm circle, you should know that a
tire offers a maximum of 100 % transmissibility. It is all the
same for the tire whether we require 100 % in the direction of
braking or in the direction of the acting lateral force, e.g. when
driving round curves. If we drive into a curve too fast and the
tire requires 100 % transmissibility as cornering force, the tire
cannot transmit any additional brake force. In spite of the ABS
the car is carried out of the curve. The relationship between
brake force B and cornering force S is shown very clearly in
the Kamm circle. If we put a vehicle wheel in this circle, the
relationship becomes even clearer. In this relationship: as long
as the acting forces and the resulting force remain within the
circle, the vehicle is stable to drive. If a force exceeds the
circle, the vehicle leaves the road.
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Dry concrete
Friction coefficient
Typical slip curves

For the various carriageway conditions the adhesion coefficients were plotted. The typical course of the curves is always the same. The only special feature is shown by the
curve for freshly fallen snow, for this curve increases at 100 %
slip. In a vehicle without ABS, the wheel locks on braking and
therefore pushes a wedge before it. This wedge of loose surface or freshly fallen snow means and increased resistance
and as a result the stopping distance is shorter. This reduction in stopping distance is not possible with a vehicle with
ABS, as the wheel does not lock. On these surfaces the stopping distance with ABS is longer than without ABS. The reason for this is based in physics and not in the Anti-Lock
System. However, as mentioned before, ABS is not about the
stopping distance, but maneuverability and driving stability,
for with ABS you can steer round an obstacle. A device with
locking wheels without ABS cannot be steered. So what use
then is the shorter stopping distance if the vehicle has already
hit the car in front, because you did not have a chance to
steer round the obstacle?
Wet concrete
Snow
Ice
Slip
<Typical slip curves>
Cornering
side force
KAMM circle
Braking force
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Brake and cornering force

- Brake force
When depressing the brake pedal the brake force increases
to the maximum, then the brake force decreases until the
wheel locks.
ABS-Control range
Stable
Unstable
- Cornering force
Brake force
The cornering force is a maximum when the wheel is

turning freely with zero slip. When braking the cornering
force falls to zero if the wheel locks (slip 100 %).
- ABS operating range
The operating range starts just before the maximum brake
force and ends in maximum, for the unstable range then
begins, in which no further modulation is possible. The
ABS controls the regulation of the brake pressure so that
the brake force only becomes great enough for a sufficient
proportion of cornering force to remain. With ABS we
remain in the Kamm circle as long as the car is driving
sensibly. We will leave driving physics with these
statements and turn to the braking systems with and
without ABS.
Cornering force
Slip
Basic ABS Controls

Brake pressure
Applications of the ABS control unit

The signals produced by the wheel sensors are evaluated in
the electronic control unit. From the information received, the
control unit must first compute the following variables:
Reference speed
Vehicle speed
Wheel speed
- Wheel speed
- Reference speed
- Deceleration
- Slip
Reference speed
The reference speed is the mean, I.e. average speed of all wheel speeds determined by simple approximation.
Simplified ABS control
If, during braking, one wheel speed deviates from the reference speed, the ABS control unit attempts to correct that
wheel speed by modulating the brake pressure until it again matches the reference speed. When all four wheels tend to
lock, all four wheels speeds suddenly deviate from the previously determined reference speed. In that case, the control
cycle is initiated again in order to again correct the wheel speed by modulating the brake pressure.
Selector low control
This control is used for regulating the brake pressure for rear axle during ABS operation. This control uses lower
adhesion coefficient to prevent the rear wheels from locking.
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EBD (ELECTRONIC BRAKE FORCE DISTRIBUTION) SYSTEM

As an add-on logic to the ABS base algorithm, EBD works in
a range in which the intervention thresholds for ABS control
can not be reached.
EBD ensures that the rear wheels are sensitively monitored
for slip with respect to the front axle. If slip is detected, the
inlet valves for the rear wheels are switched to pressure hold
to prevent a further increase in pressure at the rear-wheel
breaks, thus electronically reproducing a pressure-reduction
function at the rear-wheel brakes.
ABS features an enhanced algorithm which includes control
of the brake force distribution between the front and rear axles.
This is called Electronic Brake Distribution. In an unloading
car condition the brake efficiency is comparable to the conventional system but for a fully loaden vehicle the efficiency of
the EBD system is higher due to the better use of rear axle
braking capability.
Rearaxle braking force
System Description
Front axle braking force
Service precautions
Observe the following general precautions during any
ABS/TCS service. Failure to adhere to these precautions may result in ABS/TCS system damage.
1. Disconnect the EBCM harness connector before
performing the electric welding procedures.
The Benefits of EBD

Elimination of conventional proportioning valve EBD utilizes
the existing rear axle wheel speed sensor to monitor rear
wheel slip.
Based on many variables in algorithm a pressure hold,
increase and/or decrease pulsetrain may be triggered at
the rear wheels insuring vehicle stability.
Vehicle approaches the ideal brake force distribution (front
to rear).
Constant brake force distribution during vehicle lifetime.
EBD function is monitored via ABS safety logic
(conventional proportioning valves are not monitorable).
Keep alive function.
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2. Carefully note the routing of the ABS/TCS wiring

and wiring components during removal. The ABS/
TCS components are extremely sensitive to EMI
(eletromagnetic interference). Proper mounting is
critical during component service.
3. Disconnect the EBCM connector with the ignition
OFF.
4. Do not hang the suspension components from
the wheel speed sensor cables. The cables may
be damaged.
5. Do not use petroleum based fluids in the master
cylinder. Do not use any containers previously
used for petroleum based fluids. Petroleum
causes swelling and distortion of the rubber
components in the hydraulic brake system,
resulting in water entering the system and
lowering the fluid boiling point.
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ON-VEHICLE SERVICE
Service Precautions
[Notice]
Brake Fluid may irritate eyes and skin. In case of contact,
take the following actions:
Eye contact - rinse thoroughly with water.
Skin contact - wash with soap and water.
Ingestion - consult a physician immediately.
[Notice]
To help avoid personal injury due to poor braking. DO
NOT Tap into the vehicles brake system to operate a
trailer brake system.
[Notice]
When fasteners are removed, always reinstall them at the
same location from which they were removed. If a fastener
needs to be replaced, use the correct part number fastener
for is not available, a fastener of equal size and strength
(or stronger) may be used. Fasteners that are not reused,
and those requiring thread-locking compound will be
called out. The correct torque values must be used when
installing fasteners that require them. If the above
procedures are not followed, parts or system damage
could result.
[Notice]
Use only DOT-3 equivalent hydraulic brake fluid. The use
of DOT-5 (silicone) brake fluid is not recommended.
Reduced brake performance or durability may result.
Electronic system service precautions

Take care to avoid electronic brake control module (HECU)
circuit overloading. In testing for opens or shorts, do not
ground or apply voltage to any circuit unless instructed to
do so by the diagnostic procedure.
Test circuits only with a high-impedance multi-meter. Never
remove or apply power to any control module with the ignition switch in the ON position. Always turn the ignition to
the OFF position before removing or connecting battery
cables, fuses or connectors.
General service precautions

Disconnect the HECU connector before performing any
vehicle welding work using an electric arc welder.
Do not attempt to disassemble any component designated
as nonserviceable. The hydraulic modulator and the HECU
can be seperated. (There is however no access to repair
the each components.)
Bleeding system
Replacement modulators are shipped already filled and
bled. In normal procedures requiring removal of the
modulator, such as to replace the HECU, air will not enter
the modulator, and normal bleeding will be all that is
needed.
If air enters the hydraulic modulator, or if an unfilled modulator is installed, use the brake bleeding program in the
scan tool to bleed the modulator. Manual bleeding of the
hydraulic modulator is not possible.
[Notice]
Avoid spilling brake fluid on any the vehicles painted
surfaces, wiring, cables or electrical connectors. Brake
fluid will damage paint and electrical connections. If
any fluid is spilled on the vehicle, flush the area with
water to lessen the damage.
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2. COMPONENTS AND LOCATION

Newly introduced ABS has a different shape of integrated hydraulic modulator and HECU (Hydraulic and Electronic
Control Unit) compared to existing ABS. And, the wheel speed sensor uses different method to detect wheel speed. The
basic function of the ABS that maintains the vehicle stability by controlling the steerability of the vehicle when braking
has not been changed.
Wheel speed sensor - Rear
Wheel speed sensor - Front
ABS HECU
ABS & EBD warning lamp
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3. INPUT AND OUTPUT DIAGRAM
Battery + (hydraulic valve

and ECU power supply)
CAN LO
CAN HI
Battery +
(pump supply power)
IG1
Brake switch
Wheel speed sensor (FL)
H
E
C
U
ABS warning lamp

(instrument panel)
Diagnosis connector pin
no.8
Wheel speed sensor (FR)

Ground (pump)
Wheel speed sensor (RL)
Ground (valve)
Wheel speed sensor (RR)
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4. ELECTRICAL CIRCUIT
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5. HYDRAULIC CIRCUIT DIAGRAM

Hydraulic Circuit of ABS
Master cylinder
Primary
circuit
Secondary
circuit
Damping
chamber
Pump
Low pressure
accumulator
Inlet
valve
(FR)
Inlet
valve
(FL)
Outlet valve
(FR)
Inlet valve
(all rear
wheel)
Outlet valve
(FL)
Wheel (FR)
Low pressure
accumulator
Wheel (FL)
Outlet valve
(all rear wheel)
Wheel (RR)
Wheel (RL)
The vehicle equipped only with the ABS controls the wheels braking force using three 3-channel 4-sensor method. The
front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel
valves system with two inlet valves and two outlet valves. The rear wheels that are the secondary circuit of the brake
system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is similar to the one
from the previous model.
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ABS Circuit Per ABS Operation Range

Hydraulic Pressure Circuit when ABS is Not Operating
Low pressure
chamber
Pump
Inlet valve
Outlet valve
The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via
the normal open inlet valve. At this moment, the normally-closed outlet valve is closed. The speed of the wheel that
hydraulic pressure is delivered reduces gradually .
No Hydraulic Pressure Circuit when ABS is Operating
Low pressure
chamber
Inlet valve
Pump
Outlet valve
Constant pressure
As hydraulic pressure on each wheel increases, the wheel tends to lock. In order to prevent the wheel from locking, the
hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure
increases. At this moment, the outlet valve is closed. This procedure helps the wheel to maintain a stable hydraulic
pressure.
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Pressure Decreases in the Circuit when ABS is Operating
Low pressure
chamber
Pump
Inlet valve
Outlet valve
Pressure decreases
Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases.
This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without
locking the wheels. In order to prevent from hydraulic pressure increases, the inlet valve is closed and the outlet valve is
opened. Also, the oil is sent to the low pressure changer and the wheel speed increases again. The ABS ECU operates
the pump to circulate the oil in the low pressure chamber to the master cylinder. This may make the driver to feel the
brake pedal vibration and some noises.
Pressure Increases in the Circuit when ABS is Operating
Low pressure
chamber
Pump
Inlet valve
Outlet valve
Pressure increases
As the wheel speed increases, the inlet valve opens and the wheels pressure increases due to the master cylinder
pressure. The oil in the low pressure chamber circulates to the wheel by the pump and the wheel speed decreases as
the hydraulic pressure at wheel increases. This operation continues repetitively until there are no signs that the ECU is
locking the wheels. When the ABS hydraulic pressure control takes place, there may be some vibration and noises at
the brake pedal.
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6. COMPONENTS DESCRIPTION
HECU (Hydraulic & Electronic
Control Unit)
HECU consists of motor pump (1), solenoid valve (2) and ECU
(3).
ECU connector has 47 pins and the number of valves in valve
body is 6 when equipped with only ABS and 12 when equipped
with ESP system.
Motor Pump
The motor is operated when ABS is activated. The cam-shaped
output shaft of the motor enables the brake system to receive
and supply the brake fluid during the motor operation.
Valve Body
The cam bushing is installed between plungers and it draws
and discharges the brake fluid.
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(Pumping)
When the cam pushes the left plunger during motor operation,
the system pressure is generated in the left cylinder. At this
time, the right plunger is expanded by spring force and the
expanded volume of the right cylinder draws the brake fluid.
ECU (Including Solenoid Valves

ESP Equipped Model)
HECU controls the hydraulic valves by supplying or cutting off
the voltage to solenoid valves depending on the wheel speed
and other information from wheel speed sensors.
The figure shown in left side is for ESP ECU. There are two
channels for front wheels and one channel for rear wheels.
Each channel has one inlet and one outlet valve, therefore,
there are six solenoid valves.
(ECU lower cover)

The electrical components are weak to moisture. To protect
ECU, GoreTex-based plate is used at ECU lower cover. The
vent hall (arrow) allows air to ventilate but does not allow moisture to penetrate.
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Active Wheel Speed Sensor

Function of Active Wheel Sensor
The speed sensor used in traditional ABS is made of permanent magnet and transmits the output voltage that changes
as the wheel rotor rotates to the HECU system. New wheel speed sensor detects the wheel speed through the current
value that depends on the resistance that changes according to the magnetic field by using four resisters and supplying
the 12 V power supply to the sensor.
< Front wheel speed sensor >
< Rear wheel speed sensor >
<Wheatstone bridge>
< Active type >
Active type wheel speed sensor generate square wave insteal of sine wave
Specifications
Item
Specifications
Supplying voltage
DC 12V
Air gap
Output current (vehicle speed: at 2.75 km/h)
Tightening torque
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Front: 0.335 ~ 0.945 mm

Rear: 0.309 ~ 0.958 mm
Reference
Cannot measure the air gap
7mA (Lo) ~ 14mA (Hi) +20 % / -16 %

Front: 19 ~ 25 Nm
Rear: 6 ~ 10 Nm
7.5 ~ 20 V
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HECU Assembly
Preceding Work: Disassemble the battery negative
cable.
1. Unscrew battery mounting bracket bolts (12 mm - 2EA)
and remove battery assembly.
2. Unscrew preheating relay mounting bracket bolts (12 mm

- 2EA) and battery tray mounting bolts (12 mm - 4EA).
3. Disconnect the control unit connector.
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4. Disconnect the primary and secondary master cylinder

pipes from HECU.
Tightening torque
15 ~ 19 Nm
5. Disconnect the front and rear wheel brake pipes.

Tightening torque
15 ~ 19 Nm
Front Rear RH/LH
Secondary
FL: Front Left
Primary
FR: Front Right
[Notice]
Be careful not to damage the HECU pipe and nut thread when reinstall.
6. Unscrew the HECU mounting nuts (2EA), and remove it.

[Notice]
Do not attempt to disassemble the HECU assembly.
Wrap the end of pipes and HECU to prevent comtaminating.

8. After reinstallation, add some oil and perform the brake
air bleeding.
[Notice]
When you install a new HECU to the vehicle, Coding is excuted automatically.
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Front Wheel Speed Sensor

1. Disconnect the battery negative cable.
2. Disconnect the front wheel speed sensor connector.
3. Remove one of self-locking bolt.

Tightening torque
Front wheel speed sensor
19 ~ 25 mm
Airgap
0.369 ~ 1.213 mm
4. Remove wheel speed sensor.

5. When install, clean the sensing area and replace the
self-locking bolt with new one.
Rear Wheel Speed Sensor

2. Disconnect the speed sensor connector.
3. Remove one of self-locking bolt.

4. Remove rear wheel speed sensor.
Tightening torque
Rear wheel speed sensor
19 ~ 25 Nm
Airgap
0.3677 ~ 1.229 mm
5. When install, clean the sensing area and replace the

self-locking bolt with new one.
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System Fuse
The ABS/TCS system fuse and SB2 is located at the fuse
box in engine compartment.
Indicators
The ABS and TCS indicators are in instrument cluster.
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ABS FRONT TOOTH WHEEL

Removal
1. Remove the disc brake rotor. Refer to Front Disc Brakes
Section.
2. Remove the ABS front tooth wheel using the ABS tooth
wheel puller (1).
Installation
1. Install the ABS front tooth wheel using the ABS tooth
wheel installer (2).
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Application
661 589 16 33 00
ABS tooth wheel puller
661 589 17 33 00
ABS tooth wheel installer
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ESP SYSTEM
Principle of ESP
ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic reactions in dangerous situations,
and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for actuating the
brake. This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to
under-steering or over-steering during cornering.
The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor
under the steering column detect the spin present at any wheels during over-steering, under-steering or cornering. The
ESP ECU controls against over-steering or under-steering during cornering by controlling the vehicle stability using the
input values from the sensors and applying the brakes independently to the corresponding wheels.
The system also controls during cornering by detecting the moment right before the spin and automatically limiting the
engine output (coupled with the ASR system).
Under steering
Over steering
Desired
course
With ESP
Without
ESP
Desired
course
With ESP
Braked
wheel
Braking force
Without
ESP
Compensating yaw
moment
Braked
wheel
Compensating yaw
moment
Braking force
Understeering
Understeering is when the steering wheel is steered to a
certain angle during driving and the front tires slip toward
the reverse direction of the desired direction. Generally,
vehicles are designed to have under steering. The vehicle
can return back to inside of cornering line when the steering wheel is steered toward the inside even when the vehicle front is slipped outward. As the centrifugal force
increases, the tires can easily lose the traction and the
vehicle tends to slip outward when the curve angle gets
bigger and the speed increases.
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Oversteering
Oversteering is when the steering wheel is steered to a
certain angle during driving and the rear tires slip outward
losing traction. When compared with under steering
vehicles, the controlling of the vehicle is difficult during
cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed
increases.
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ESP controls during under steering

The ESP system recognizes the directional angle with the
steering wheel angle sensor and senses the slipping route
that occurs reversely against the vehicle cornering direction during understeering with the yaw rate sensor and the
lateral sensor. Then the ESP system applies the brake at
the rear inner wheel to compensate the yaw moment value.
In this way, the vehicle does not lose its driving direction
and the driver can steer the vehicle as driver intends.
ESP controls during oversteering

The ESP system recognizes the directional angle with
the steering wheel angle sensor and senses the slipping
route that occurs towards the vehicle cornering direction
during oversteering with the yaw rate sensor and the lateral sensor. Then the ESP system applies the brake at
the front outer wheel to compensate the yaw moment value.
In this way, the vehicle does not lose its driving direction
and the driver can steer the vehicle as he or she intends.
ESP Control
The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the
vehicle driving conditions. For example, when the brakes are applied during cornering at the speed of 100 km/h, the ABS
system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel. And
when yaw rate sensor detects the rate exceeding 4/seconds, the ESP system is activated to apply the brake force
to the corresponding wheel to compensate the yaw moment with the vehicle stability control function. When various
systems operate simultaneously under a certain situation, there may be vehicle control problems due to internal malfunction of a system or simultaneous operations. In order to compensate to this problem, the ESP system sets the
priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and ABS. The order may be
changed depending on the vehicle driving situations and driving conditions. As the single-track vehicle model used for
the calculations is only valid for a vehicle moving forward, ESP intervention never takes place during backup.
ESP Operating ESP

range
Turning
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Turning
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Vehicle Control During Cornering

The figure below shows the vehicle controls by ESP system under various situations such as when the brake pedal is
pressed (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operating during braking. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating.
Operations
Understeering Control
Oversteering Control
ESP auto brake
Only ESP operating
Engine
control
No braking by driver
ESP auto brake
ESP auto brake

(none ABS)
: Service brake
ESP
+
Conventional
brake
(ABS not operating)
ESP auto brake

: Service brake
2 : ABS operation
1 : The slip occurs

under ESP operation
ESP
+
ABS brake
1 : The slip occurs
under ESP
operation
2 : ABS operation
2 : ASR operation
1 : The slip occurs

under ESP operation
ESP
Engine
control
+
ASR
1 : The slip occurs
under ESP
operation
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2 : ASR operation
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HBA (Hydraulic Brake Assist System)

Deceleration
Experienced drivers
Inexperienced drivers
Elderly and physically

weak drivers
Time (s)
(1) Purpose
HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast,
but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full
braking and transmits the signal calling for full brake pressure from the hydraulic booster. An inexperienced, elderly or
physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required
under emergency. The HBA System increases the braking force under urgent situations to enhance the inputted braking
force from the driver.
Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary, the
HECU system is a safety supplementary system that builds high braking force during initial braking according to
pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals.
When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or
physically weak driver, the vehicle will make abrupt stopping under normal braking situation due to high braking pressure
at each wheels.
(2) Operation
The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System
operates. There are 2 pressure sensors under the master cylinder. When the ESP ECU system determines that emergency braking is present, the pump operates, the brake fluid in the master cylinder is sent to the pump and the braking
pressure is delivered to the wheels via the inlet valves.
If the drive depress the brake pedal slowly, the pressure change is not high. In this case, only the conventional brake
system with booster is activated.
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1. HECU: (Hydraulic & Engine

conrol unit)
2. Pressure sensor
3. Wheel speed sensor
ESP Warning lamp
4. Sensor cluster:
(Yaw rate + lateral sensor +
longitudinal sensor)
5. Steering wheel angle

sensor
6. ESP off switch (Electronic

Stability Program Switch)
2WD vehicle has the longitudinal sensor in the HECU.
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Comparison with ABS System

Specifications
Name
ABS
ESP
CPU: MCU60 (32 bit)
CPU: MCU60 (32 bit)
(Hydraulic & Elec-
Clock Frequency: 28 MHz
Clock Frequency: 28 MHz
tronic Control Unit)
Memory: 128 ~ 256 KB
Memory: 256 ~ 512 KB
HECU
Location
Under battery
Each 4 wheels
Wheel speed sensor
Active Type
Active Type
Front airgap: 0.335 ~ 0.945 mm

Rear airgap: 0.309 ~ 0.958 mm
Steering wheel
angle sensor
N/A
Sensor cluster
N/A
Longitudinal sensor
Integrated in HECU
Pressure sensor
N/A
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Maximum angular velocity: 1500/Sec

Working voltage: 9 ~ 16 V
Under steering wheel
2WD: Yaw rate sensor + Lateral sensor

4WD: Yaw rate + Lateral sensor +
Under front right seat
Longitudinal sensor
Analog Output
Under master cylinder
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3. INPUT AND OUTPUT DIAGRAM

Batt. + (voltage to hydraulic v/v)
CAN LO
Battery + (voltage to pump)
CAN HI
IG1
Brake switch
STICS (Vehicle speed)
ESP switch
A/V Head unit
Signal
Wheel speed sensor (FL)
A/V system is inoperative while driving

Ground
Signal
Wheel speed sensor (FR)
Ground
Signal
Wheel speed sensor (RL)
Ground
Signal
Wheel speed sensor (RR)
E
S
P
Cluster (Vehicle speed)
ESP warning lamp

ESP lamp on while
- ESP is in operation (Flicker)
- ESP, ABS system error
- ESP off switch is pushed
Ground
ABS warning lamp

Power
source
Signal
Pressure sensor 1
Ground
Power
source
Pressure sensor 2
Signal
Ground
H
E
C
U
ABS system error
ESP buzzer
While ESP is in operation buzzer work by
every 0.1sec
Diagnostic connector
IG1
ST1
SWAS
ST2
STN
Ground (Pump)
Ground
Power
source
Ground (Valve)
CAN-H
Sensor cluster
CAN-L
Ground
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4. ELECTRICAL CIRCUIT DIAGRAM

ABS/ESP
Wheel Speed Sensor, Stop Lamp, Diagnosis, Warnung Lamp (ABS/ESP)
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Brake Pressure Sensor, ESP Sensor, Sensor Cluster, ESP OFF Switch
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5. HYDRAULIC CIRCUIT DIAGRAM
Pressure
sensor
Damper
(primary circuit)
Damper
(secondary circuit)
Separation
valve (NO)
Separation valve
(NO)
Damping chamber
Shuttle
valve
Shuttle valve
Pump
Low pressure
accumulator
FR
inlet valve
(NO)
FL inlet
valve
(NO)
RR
inlet valve
(NO)
RL
inlet valve
(NO)
FR
outlet
valve(NC)
FL
outlet
valve(NC)
RR
outlet
valve(NC)
RL
outlet
valve(NC)
Wheel (FR)
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Wheel (FL)
Wheel (RR)
Wheel (RL)
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System Overview
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And when
equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS system
only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD only, the
internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary
circuit. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes,
the normally-open separation valve and the inlet valve are open, whereas the normally-closed shuttle valve and the outlet
valve are closed. When the ESP system is operating, the normally-open separation valve will be closed by the solenoid
valve operation and the hydraulic circuit will be established by the shuttle valve. Then, the inlet and outlet valves will be
closed or open depending on the braking pressure increase, decrease or unchanged conditions.
The warning lamp comes on and warning beep sounds when the ESP is operating
When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flickers and
beep comes on every 0.1 seconds. The ESP operation shows that the vehicle stability is extremely unstable
and it is used to warn the driver. The ESP system is just a supplementary system for the vehicle motion and it
cannot control the vehicle when it exceeds the physical limits. Do not solely rely on the system but be advised
to drive the vehicle safely.
Driving feeling when the ESP is operating

When the ESP system activates, the driving feeling can be different depending on vehicle driving conditions. For
example, you will feel differently when the ESP system is activated during when ABS is operating with the
brakes applied and when brakes are not applied on a curve. Thus, the ESP system would make the driver feel
more abruptly when the brakes are applied during the ESP system activation.
Noise and vibration that driver senses when the ESP is operating
The ESP system may transfer noise and vibration to the driver due to the pressure changes caused by the
motor and valve operations in a very short period of time. Extreme cornering will trigger the ESP operation and
this will make the driver feel noise and vibration due to sudden brake application. Also, the ESP system controls
the engine output. So, the driver may notice the engine output decrease even when the accelerator pedal is
being applied.
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(1) ESP Hydraulic unit in idling and normal braking position
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and
the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel
via the separation valve and inlet valve.
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(2) When applied ABS (decreased pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve
Outlet valve
The pressure decreases just before the wheel speed drops and the wheels. The inlet valve closes and the outlet valve
opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
Then the pump operates to allow fast oil drainage.
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(3) When applied ABS (maintained pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Inlet valve
Outlet valve
The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By
closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more. During ESP operation, the
separation valve closes and only the shuttle valve at the pump opens.
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(4) When applied ABS (increased pressure)
Low pressure
chamber
Shuttle valve
Separation valve
Pump
Outlet valve
Inlet valve
The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is
operated.
When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the
corresponding wheel gets locked.
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(5) Hydraulic Diagram of HBA
Low pressure
chamber
Shuttle valve
Outlet valve
Separation valve
Inlet valve
Pump
Rear wheel
Outlet valve
Inlet valve
Front wheel
The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation.
When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of
the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immediately to apply the brake pressure at the wheels.
Then, the pressure in the pump increases until just before the corresponding wheel gets locked. The motor still keeps
rotating and the outlet valve and the separation valve are will stay closed. When the wheel starts to lock, the HBA
function cancels and switches to ABS operation.
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6. COMPONENTS DESCRIPTION
HECU (Hydraulic and Electronic Control Unit)
HECU Installed in a Vehicle
RL: Rear left

Secondary
RR: Rear right
FL: Front left
Primary
FR: Front right
HECU consists of motor pump, solenoid valve and ECU.

ECU connector has 47 pins and the number of valves in valve body is 12 when equipped with ESP(6 valve for ABS/EBD),
and they cannot be disassembled.
Comparison between ESP HECU and ABS/EBD HECU
ABS/EBD HECU (2 ports 3 chnnels)
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ESP HECU (2 ports 4 chnnels)
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ECU (Electronic Control Unit)

The electronic control unit performs the following functions:
- controlling the ABS and ESP
- cotinuous monitoring of all electrical components
In the integrated control unit, the coils of the solenoid valves
are integrated into the control unit housing. The necessary
relays are mounted on the circuit board of the electronic control unit.
- yaw rate
- G sensor
- lateral/longitudinal acceleration
- pressure in hydraulic system
- wheel speed
- reference speed
- deceleration
- slip
# ABS control
If during braking, one wheel speed deviates from the reference
speed, the ABS control unit attempts to correct that wheel by
modulating the brake pressure until it again matches the reference speed. When all four wheels tend to lock, all four wheels
speeds suddenly deviate from the previously determined reference speed. In that case, the control cycle is initiated again
in order to again correct the wheel speed by modulating the
brake pressure.
Brake pressure
Reference speed
Vehicle speed
Wheel speed
Hydraulic Control Unit

The pump and the valve body are grouped together in one
housing, forming one compact unit with the electric motor.
Four pairs of valves (4 inlet valves, 4 outlet valves) are provided
for modulating the pressure at the wheels plus two isolating
valves and two electrically operated shuttle valves.
Mote pump
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Valve body
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Connector
Pin no.
1
2
3
Name
Battery (B+)
Self diagnosis (K-Line)
Steering wheel angle sensor (STN)
Current Tange
Max. 30 A
Max.100 mA
Max. 10 mA
Voltage Range
0 ~ 18 V
0 ~ 18 V
0 ~18 V
ABS ECU
O
O
-
4
5
6
7
IGN1
Steering wheel angle sensor ground
Sensor cluster power
Steering wheel angle sensor power
Max. 200 mA
Max. 100 mA
Max. 250 mA
Max. 10 mA
0 ~ 18 V
0V
0 ~ 18 V
0 ~ 18 V
O
-
Max. 100 mA
0 ~ 18 V
0 ~ 18 V
0V
O
O
8
9
10
11
CAN (High)
12
13
14
15
16
CAN (Low)
Ground
Max. 100 mA
Max. 20 A
17
18
19
Pressure sensor (No.1) power

Pressure sensor (No.1) ground
Max. 20 mA
Max. 20 mA
5V
0V
20
21
22
23
Pressure
Pressure
Pressure
Pressure
Max.
Max.
Max.
Max.
5
0
5
5
24
25
26
27
28
Sensor cluster CAN (Low)

Steering wheel angle sensor (ST2)
Max. 10 mA
Max. 10 mA
0 ~ 18 V
1.3 ~ 4.1 V
29
30
31
32
Sensor cluster CAN (HIGH)

Steering wheel angle sensor (ST1)
Sensor cluster ground
Battery (B+)
Max. 10 mA
Max. 10 mA
Max. 250 mA
Max. 20 A
0 ~ 18 V
1.3 ~ 4.1 V
0V
0 ~ 18 V
33
34
35
36
37
Wheel speed sensor ground (FR)

Wheel speed sensor ground signal (FR)
Wheel speed sensor ground signal (RL)
Wheel speed sensor ground ground (RL)
mA
mA
0V
0 ~ 18 V
-
O
O
-
mA
mA
Max. 10 mA
0 ~ 18 V
0V
0 ~ 18 V
O
O
-
Max. 10 mA
3 ~ 45 mA
3 ~ 45 mA
Max. 20 mA
0 ~ 18 V
0V
0 ~ 18 V
0 ~ 18 V
O
O
O
O
3 ~ 45 mA
3 ~ 45 mA
Max. 30 A
0 ~ 18 V
0V
0V
O
O
O
38
39
40
41
42
43
44
45
46
47
sensor (No.1) signal

sensor (No.2) ground
sensor (No.2) power
sensor (No.2) signal
ESP OFF switch

Stop lamp switch
Wheel speed sensor
Wheel speed sensor
ABS warning lamp
Wheel speed sensor
Wheel speed sensor
Ground
ABS/ESP SYSTEM
STAVIC - 2004.09
ground ground (RR)

ground signal (RR)
ground signal (FL)
ground ground (FL)
10
20
20
10
3 ~ 45
3 ~ 45
3 ~ 45
3 ~ 45
mA
mA
mA
mA
V
V
V
V
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Wheel Speed Sensor

Active Wheel Sensor
- Measuring bridge with four resisters
- Measuring the current
- Supplying the voltage (12 V)
- Amplifier/comparison measuring device
Function of Active Sensor System

The basic tone wheel and the magnetized encoder wheel to
activate the sensor. When the vehicle is moving, the sine wave
signal is changed in the magnetic field of wheatstone bridge
due to the rotation of tone wheel. This can be done directly by
ABS control unit.
Active Sensor Element of Encoder Wheel

This sensor has the measuring bridge integrated plastic housing and is fixed to small permanent magnet. Four lead wires
that receive electrical output value are connected to the IC
integrated plastic housing. Two connecting pins are used for
signal output and voltage supply.
Permanent
magnet
Sensor filament
Specifications
Description
Specifications
Supplying voltage
DC 12 V
Air gap
Output current
(vehicle speed at 2.75 Km/h)
Tightening torque
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Front: 0.335 ~ 0.945 mm

Rear: 0.309 ~ 0.958 mm
Reference
Cannot measure the air gap
7 mA (Lo) ~ 14 mA (Hi) +20 % / -16 %

Front: 19 ~ 25 Nm
Rear: 6 ~ 10 Nm
7.5 ~ 20 V
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SWAS : Steering Wheel Angle Sensor

The steering wheel angle sensor is located between clock spring and multifunction switch. This sensor is used for
recognition of drivers intends. If the sensor is replaced with new one, it can detect the neutral position after the vehicle
is moving over 20 km/h for more than 5 seconds.
1. Clock spring
2. Multi-function switch
3. SWAS (Steering Wheel Angle Sensor)
Specifications
Descriptions
Specifications
Working voltage
9 ~ 16 V
Max. output current
10 mA
Detected max. angular velocity
1500/S
Working temperature
-30 ~ 75C
Supplying voltage
9 ~ 16 V(battery voltage)
When short
0V
When short to sensor
Power voltage - 0.7 V
Output voltage (HI)
Approx. 3.50 V (3.0 ~ 4.1 V)
Output voltage (LO)
Approx. 1.50 V (1.3 ~ 2.0 V)
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Steering wheel angle

sensor connector
LED
Steering column
Phototransistor
Slotted plate
Steering wheel angle
The steering wheel angle sensor is integrated with the phototransistor and the LED and there is a slotted plate between
them. When the inner slotted plate rotates with the steering column shaft when the steering wheel is turned, the voltage
occurs through the holes. The detected voltage will be transmitted to the ESP unit as a pulse from the 3 terminals.
Then, the two voltage pulses are used to get the average value for detecting the steering wheel position and its angle
speed. And the other pulse is used for checking the alignment of the steering wheel.
Steering
Wheel
Angle
Sensor
(SWAS)
ESP
unit
With ESP
Working voltage
9 ~16 V
Number of pulse
per revolution
45 Pulses /1rev
Duty
Approx. 50 %
High - V
3.0 ~ 4.1 V
Low - V
1.3 ~ 2.0 V
ST1 and ST2
Detects steering wheel

angle and angular velocity as an average value
STN
Detects the center value

of steering wheel
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Center line of steering wheel

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Sensor Cluster
The lateral sensor, logitudinal sensor and the yaw rate sensor are important components of the Electronic Stability
Program. The cluster links these sensors to an on-board computer unit and to a CAN interface, incased in a sturdy
housing, that is mounted on the chassis. Its modular concept allows the integration of further sensor functions.
Location
Internal Electric Circuit of Sensor Cluster
Sensor cluster
Power supply
Power supply
circuit
Yaw rate sensor
Micro controller
(self diagnosis)
ECU
A/D converter
Lateral sensor
CAN
CAN module
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Longitudinal sensor
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Sensor Cluster Circuit
Power
Ground
Power
Sensor cluster
ESP unit
Specification
(sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal acceleration sensor)
Descriptions
Specifications
Supplying voltage
Approx. 8 ~ 16 V
Output voltage when stop
Approx. 2.5 V (Ignition switch ON)
Output range
0.2 ~ 4.8 V
Operation start speed
-75/s ~ +75/s
Yaw Rate Sensor

The yaw rate sensor relies on the action of micro-scopic tuning forks. The plane in which these forks vibrate shifts when
the car turns around its vertical axis. This shift is evaluated
electronically.
A faulty yaw rate sensor produces an output signal of 0 V.
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Installation position
Tuning forks vertical
Required accuracy of position: max. 3 tolerance to
maintain full comfort
Failure to maintain the specified installation position will
result in asymmetrical control
Lateral/Longitudinal Acceleration
Sensor
These sensors sense the lateral/longitudinal acceleration of
the vehicle and located in sensor cluster. For 4WD vehicle,
the longitudinal sensor is located in sensor cluster and the
functions are same only except the direction. The lateral acceleration sensor detects the movement of lateral direction
and the longitudinal acceleration sensor detects the movement of longitudinal direction (driving direction).
Between two electrically charged stationary plates having the
same polarity, an electrically charged silicon element having
the opposite polarity is attached to the end of a cantilever
arm. Between these three plates, two electric fields are generated by the capacitors C1 and C2. The capacitances of C1
and C2 change in response to lateral acceleration. This change
can be used to calculate the direction and amount of lateral/
longitudinal acceleration acting on the vehicle. For 0 g lateral
acceleration, the sensor produces an output signal with a voltage of 2.5 V.
The signal of the lateral acceleration sensor alone cannot trigger an ESP intervention.
The ESP sensor cluster can be considered as one module.
The measured value by lateral/longitudinal and yaw rate sensors is transmitted to ESP unit via two CAN lines.
When a sensor is faulty, the sensor cluster produces an output signal of 0 V (fail safe function).
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Pressure Sensor
Location
1. Master cylinder
4. Inside of pressure sensor
2. Primary pressure sensor
5. Connector
3. Second pressure sensor
Pressure Sensor Circuit

Ground
HBA operating conditions with output value from
pressure sensor:
Power
- pressure: 20 bar
Signal output
- pressure deviation: over 1500 bar/sec

<Primary pressure sensor>
- vehicle speed: over 7 km/h
Ground
Power
Signal output
<Secondary pressure sensor>
<ESP unit>
Specifications
Descriptions
Specifications
Supplying voltage
4.75 ~ 5.25 V
Output range
0.25 ~ 4.75 V
Output voltage when stop
2.5 V
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Description
a. The pressure sensor senses the drivers braking
intentions (braking while an ESP intervention is in
progress) and detects the precharging pressure.
b. The sensor consists of two ceramic disks, one of which

is stationary and the other movable. The distance
between these disks changes when pressure is applied.
c. The pressure sensors operate on the principle of changing

capacitance (a).
The distance (s) between the disks and, thus, the
capacitance changes when pressure is applied to the
movable disk by a braking intervention.
Brake not
applied
d. When brake pressure is applied from the master cylinder,

the ceramic disk moves towards the fixed ceramic disk
and the electric charge volume changes accordingly.
Brake
applied
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If two signals from pressure sensor deviates from the specified value, HECU determines the sensor is faulty. The sensor
output is analog signal that is proportional to voltage and the HECU recognized the pressure value as signal value
against supplying voltage.
Maximum measurable pressure: 170 bar
Linear changes of about 0.5 volts when the brake is not operating and 4.75 volts when the brake is operating.
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ESP OFF Switch

ESP OFF switch is located at center switch panel. When pressing the switch, the ESP warning lamp lights up and ESP
and TCS function is deactivated.
However, the ABS function is still activated.
Automatic coding
When replacing the HECU with new one, it is coded automatically. Therefore, additional coding operation is not needed.
When the existing ECU installed to another vehicle or a new HECU recognizes that the coded data is not matched with
the vehicle, the warning lamp lights up and ABS/ESP is not activated.
The HECU is coded when it is initially installed to the vehicle, and once coded data cannot be changed.
* If DTC C1170 (5170) is generated during automatic coding, clear it with a scan tool to resume automatic coding
process.
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WARNING LAMP AND INDICATOR

ESP Warning Lamp Blinking in Control
ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to
warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is operated for
a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds and the buzzer
sounds for at least 1.4 seconds with 100 ms interval.
ON
ESP operation
(including ASR)
OFF
Min. 4 times
ON
ESP warning lamp
OFF
Min. 1.4 sec

ON
ESP buzzer
OFF
ESP System Cancellation Using the ESP OFF Switch

When the ESP switch at the center switch panel is pushed (for over approximately 150 ms), the ESP system will be
cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP
warning lamp on the instrument panel comes on.
The detailed operation procedures are as follows:
1) The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2) The switch returns to normal position when the OFF switch is released.
3) The ESP system will be cancelled after approximately 150 ms.
Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx. 150
ms) from releasing the switch to the original position. The ESP system does not get canceled immediately when the
ESP warning lamp is turned on by pressing the ESP OFF switch.
When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And the
basic ABS system will operate.
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Resuming the ESP System by Using the ESP OFF Switch

The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch at
the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating.
The detailed operation procedures are as follows.
1) The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms.
2) The switch returns to normal position when the OFF switch is released.
3) The ESP system will be resumed after approx. 150 ms.
RELEASE
PUSH
RELEASE
PUSH
HI
Disabled range
ESP operation
LO
ESP function
(including ASR)
ON
OFF
ON
ESP warning lamp
OFF
[Notice]
When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed when ignition
switch is turned on again.
When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate.
The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the ESP OFF mode
and the ESP warning lamp will not be changed.
When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be
turned on.
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ESP OFF Switch Monitoring

When the ESP unit recognizes that the ESP OFF switch is pushed for over 60 seconds, the ESP unit determines it as
a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 60 seconds.
However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and then goes out
when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP unit resets the ESP
OFF switch for approx. 3.5 seconds.
Push
HI
ESP operation
Release
LO
60 sec
3.5 sec
Return to switch signal
Reset to normal condition
ON
ESP function
(including ASR)
OFF
Cancellation of ESP OFF mode
Turning the ESP warning lamp off
ON
ESP warning lamp
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OFF
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ESP Warning Lamp Operation Depending on System Conditions

The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function) is
working.
Warning Lamp
Controls
EBD
ABS
ASR
ABD
Vehicle
yaw
control
OFF
BLINKS
WHEN ESP
OPERATION
INTERMITTENT BEEP
SOUNDS WHEN ESP
OPERATION
OFF
ON
OFF
OFF
ON
ON
OFF
EBD
ABS
ESP
ESP
W/L
W/L
W/L
BUZZER
ON
ON
ON
OFF
OFF
ESP fault
OFF
ABS fault
Initial start
(for 1.8 sec)
Normal mode
ON
ON
ON
OFF
st
OFF
ON
ON
OFF
nd
ON
ON
ON
OFF
High battery voltage
ON
ON
ON
OFF
High brake pad temp.
OFF
OFF
ON
OFF
**O
ESP-OFF mode
OFF
OFF
ON
OFF
*O
Entering diag. mode
ON
ON
ON
OFF
System fault
Low batt. voltage 1
Low batt. voltage 2
*) When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compensate
the vehicle stability (posture) during ESP operation.
* *) The ASR controls only engine control
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
56
4K

HECU Assembly
Preceding Work: Disassemble the battery negative
cable.
1. Unscrew battery mounting bracket bolts (12M - 2EA)
and remove battery assembly.
2. Unscrew preheating relay mounting bracket bolts (12M 2EA) and battery tray mounting bolts (12M - 4EA).
3. Disconnect the control unit connector.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
57
4. Disconnect the primary and secondary master cylinder

pipes from HECU.
Tightening torque
20 ~ 24 Nm
5. Disconnect the front and rear wheel brake pipes.

Tightening torque
15 ~ 19 Nm
RL: Rear left

Secondary
RR: Rear right
FL: Front left
Primary
FR: Front right
[Notice]
Be careful not to damage the HECU pipe and nut thread
when reinstall.
6. Unscrew the HECU mounting nuts (2EA), and remove it.

[Notice]
Donot attempt to disassemble the HECU assembly.
Wrap the end of pipes and HECU to prevent comtaminating.

8. After reinstallation, add some oil and perform the brake
air bleeding.
[Notice]
When you install a new HECU to the vehicle, Coding is excuted
automatically.
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
58
4K
Steering Wheel Sensor

1. Disconnect the battery negative cable and align the tires straight forward.
2. Remove the airbag module.
3. Unscrew the steering wheel mounting nut and remove the wheel.
4. Remove the I/P panel lower cover.
[Notice]
Leave marks on the column shaft(A) and on the wheel(B).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
59
5. Remove the steering column upper/lower cover.
6. Remove the contact coil.
7. Remove the steering wheel angle sensor frim the steering

wheel (combi switch).
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
60
4K
Sensor Cluster
1. Remove center panel and aircon controller.
2. Disconnect the sensor cluster connector and unscrew

the cluster mounting bolts (2EA).
3. Disassemble the sensor cluster.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
61
8. ABS/ESP TROUBLE DIAGNOSIS

DTC CODE
[O: Applied, X: N/A]
Trouble
Code
Defective Components
Descriptions
ABS
ESP
Cause
C1011
(5011)
Wheel speed sensor

front left-electrical
- Defective front LH wheel speed sensor

- Short or poor contact wire to sensor
Action
- Check the wheel speed sensor connector and HECU
connector
- Check the harness connection
Cause
C1012
(5012)
Wheel speed sensor

front left-other
- Defective front LH wheel speed sensor

- No signals from wheel speed sensor and tooth wheel
- Different number of teeth in tooth wheel
Action
- Check air gap and tooth wheel mounting
- Check the number of teeth in tooth wheel: 48
Cause
- Defective front RH wheel speed sensor
C1021
(5021)
Wheel speed sensor

front right-electrical

Action
- Check the wheel speed sensor connector and HECU
connector
Cause
- Defective front RH wheel speed sensor
C1022
(5022)
Wheel speed sensor

front right-other

- Too large air gap between wheel speed sensor and tooth
wheel
Action
Cause
- Defective rear RH wheel speed sensor
C1031
(5031)
Wheel speed sensor

rear right-electrical
Action
- Check the wheel speed sensor connector
- Check the EBCM connector
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
62
Trouble
Code
4K
Descriptions
ABS
ESP
Cause
- Defective rear RH wheel speed sensor
C1032
(5032)
Wheel speed sensor rear

right-other
- Too large air gap between wheel speed sensor and

tooth wheel
Action
Cause
C1041
(5041)
Wheel speed sensor

rear left-electrical
- Defective rear LH wheel speed sensor

Action
- Check the HECU connector
Cause
- Defective rear LH wheel speed sensor
C1042
(5042)
Wheel speed sensor

rear left-other

- Too large air gap between wheel speed sensor and
tooth wheel
Action
Cause
- Abnormal signals from pressure sensor
- Defective pressure sensor or harness
C1051
(5051)
Pressure sensor
Action
- Check the pressure sensor connector
- Check the output voltage (stop): 0.5 V
- Check the output voltage (brake applied): 0.25 ~ 4.75 V
Cause
- Internally defective steering wheel angle sensor
- Abnormal signals from steering wheel angle sensor
- Short circuit between supplying voltage output and ground
C1061
(5061)
Steering wheel Angle

sensor
- Abnormal signal voltage from steering wheel angle sensor

- Poor installation of steering wheel angle sensor and
abnormal signal
Action
- Check the harness connection of steering wheel angle
sensor
- Check the working voltage : LOW 1.3 ~ 2.0 V
HIGH 3.0 ~ 4.1 V
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
Trouble
Code
C1073
(5073)
63
Sensor cluster -electrical
Descriptions
ABS
ESP
Cause
- Operating voltage exceeds specified range
(Hi: 18.0 1.0 V / Lo: 6.5 0.5 V)
X
- Poor contact or installation of harness

Action
- Check the sensor cluster connector
- Others
Cause
- Internally defective HECU
- Abnormal A/D converter voltage: 5.0 3 %
- Abnormal supplying voltage (4.580 ~ 4.960 V) to sensor
cluster
Short circuit between supplying voltage output of
sensor cluster and ground
- Poor ground of sensor cluster (0.0 ~ 0.5 V)
C1074
(5074)
Sensor cluster-internal
Short to ground on sensor cluster

- Abnormal signals from longitudinal acceleration sensor
- Abnormal signals from lateral acceleration sensor
- Abnormal signals from yawing sensor

- Poor installation of sensor
- Defective sensor cluster
- Defective or short circuit of CAN communication line
Action
- Replace the sensor
- Initialize the sensor
Cause
C1101
(5101)
C1102
(5102)
C1111
(5111)
Battery under voltage
Battery over voltage
Disk temperature is high
- Low voltage out of specified range (9.7 0.3 V)

Action
- Check the supplying voltage
Cause
- Over voltage out of specified range (18.0 1.0 V)
Action
Cause
- Overheated brake disk due to braking force: over 500C
Action
- Stop driving for a period of time after turning off the ESP
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
64
Trouble
Code
C1201
(5201)
C1202
(5202)
4K
Brake lamp switch
Descriptions
Cause
- Mechanical defective in brake switch
- Defective brake switch harness
ABS
ESP
Action
- Check the harness and connector
ESP OFF switch
Cause
- Mechanical defective in ESP OFF switch
- Defective ESP OFF switch harness (short to ground)
Action
- Check the harness and connector for ESP OFF switch
Cause
- Abnormal supplying voltage to valve solenoid
C1301
(5301)
Valve, valve relay
Action
- Check the battery voltage
- Replace the HECU
Cause
- Too low (below 6.0 V) or no supplying voltage to pump
motor
- Over 0.93 V from pump motor voltage
C1311
(5302)
Motor pump
- Poor contact in pump motor connector

- Poor ground
Action
- Replace the HECU
Cause
C1401
(5401)
HECU hardware
- Defective A/D converter, internal voltage regulator, and

controller
- Defective sensor and short to supplying voltage line
Action
- Replace the HECU
C1501
(5501)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
No calibration or SC
checksum error
Cause
- Abnormal signals from sensors
- Poor calibration for sensors
Action
- Check and initialize the sensors
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
Trouble
Code
C1170
(5170)
65
Descriptions
ABS
ESP
(O)
(O)
Cause
- Coding error
- Defective CAN communication line
Variant coding error
- Discrepancy between HECU coding and vehicle coding

Action
- Check the HECU coding and vehicle coding
- Replace the HECU
Cause
C1601
(5601)
CAN bus off
- Defective CAN communication line

Action
- Check CAN communication line
Cause
- Short to CAN communication line
CAN timeout EMS

C1602
(5602)
C1603
(5603)
(communication error
between engine ECU
and CAN)
CAN timeout TCU

(communication error
between TCU and CAN)
- Overload to CAN communication

Action
- Check the engine ECU
- Check the CAN communication line
- Check the engine ECU connector
Cause
- Short to CAN communication line
- Overload to CAN communication
Action
- Check the TCU
- Check the engine TCU connector
Cause
C1604
(5604)
CAN timeout 4WD

(can signal error EMS)
- Defective communication with TCCU

Action
- Check the TCU
- Check the TCCU connector
C1612
(5612)
CAN timeout 4WD

(can signal error EMS)
Cause
- Defective signal transmit of Engine ECU
Action
- Check the engine ECU varient coding
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
4K
ABS/ESP Sensor Value

No
Contnet
Unit
ESP
ABS
Wheel Speed Front RH
1 km/h
Wheel Speed Front LH
1 km/h
Wheel Speed Rear RH
1 km/h
Wheel Speed Rear LH
1 km/h
Battery Voltage
0.1 V
Longitudinal Acceleration Sensor
0.01 g
- : Straight ahead
7
Lateral Aceleration Sensor
0.01 g
(Fixed Value: 0)
O
+ : Left Turn
8
Yaw Rate Sensor
0.5 deg/s
(Fixed Value: 0)
O
+ : Left Turn
9
Steering Wheel Angle Sensor
5 deg
Pressur Sensor (Primary)
1 bar
X
(Fixed Value: 0)
+ : Left Turn
10
X
(Fixed Value: 0)
X
(Fixed Value: 0)
11
Pressur Sensor (Secondary)
1 bar
X
(Fixed Value: 0)
12
EBD Control
Operation / Non-operation
13
BTCS Control
14
Engine TCS Control
15
ESP Control
16
ESP / TCS OFF Switch
ON / OFF
17
ABS Control
18
Stop Lamp Switch
ON / OFF
[O: Applied, X: N/A]
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
67
ABS/ESP Forced Operation

No
Name
Operation
Front LH Inlet
Front LH Outlet Valve
Front RH Inlet
Front RH Outlet Valve
Rear (or RL) Inlet Valve (x1)
Rear (or RL) Outlet Valve (x1)
(Rear RH Inlet Valve (x2))
(Rear RH Outlet Valve (x2))
TCS Valve Primary (x3)
10
TCS Valve Secondary (x3)
11
ESV Valve Primary (x3)
12
ESV Valve Secondary (x3)
13
14
15
Motor Pump
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
68
4K
Sensor Initialzation (SCAN 100)

INTIALIZE SENSOR(Only ESP)
INTIALIZE SENSOR
1] LONGITUDINAL ACCEL SENSOR(4WD only)
2] LATERAL ACCEL SENSOR
3] PRESSURE SENSOR
4] ABOVE 1, 2, 3 ALL SENSOR
Select one of the above items
INTIALIZE SENSOR
LONGITUAINAL ACCEL SENSOR(4WD only)

DO YOU START INITIALIZE ? (Yes/No)
CONDITION :
-
ENGINE IS NOT RUNNING.
VEHICLE STATUS IS FLAT.
DO NOT PUT THE BRAKE PEDAL.
PROCEDURE :
MUST BE FOLLOW THE ABOVE CONDITION.
IF YOU START "INITIALZE SENSOR",
ADART TO AUTOMATIC.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
4K
69
9. AIR BLEEDING
The vehicle equipped only with ABS can use the conventional air bleeding procedure, however, the vehicle equipped with
ESP should use the oil supply device with compressor to bleed the air.
Rear
Front
Oil supply
Oil return
Air bleeding should be done when:

1. After removal and installation of the brake master cylinder.
2. After removal and installation of the ABS HECU.
3. After removal and installation of the brake oil pipes and hoses.
4. After replacing the brake fluid.
5. Braking force is not made properly.
ABS/ESP SYSTEM
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
70
4K
Air bleeding procedures

1. Apply the parking brake and start the engine when the shift lever is at P position.
2. Connect the oil supply device (air bleeding device) with air compressor to brake reservoir. The oil supply device
should be filled with sufficient oil.
3. Loosen the air bleed screw in caliper and place an empty container under the screw.
4. Bleed the air in each wheel by using diagnostic device (SCAN 100). At this time, the modulator motor runs for 180
seconds.
5. Simultaneously, run the oil supply device to supply oil and depress the brake pedal repeatedly.
This procedure needs at least 3 persons for doing below jobs:
1) Collect the bleeding oil into the container.
2) Depress the brake pedal repeatedly.
3) Check the conditions of oil supply device.
6. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw.
7. Perform the same procedures at each wheel.
Notice
Replace the brake oil at every 2 years.
Notice
Always bleed the air after replacing the brake fluid or master cylinder, caliper, brake hose and pipe.
Never reuse the used brake fluid.
Do not pump the brake pedal too fast. It may cause some troubles for air bleeding operation.
Be careful not to splash the brake fluid on painted area or body.
Check the connection areas for leaks after air bleeding.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ABS/ESP SYSTEM
STAVIC - 2004.09
5A
OVERVIEW
Height adjuster (Driver/passenger)
Front seat belt
Passengers airbag
Passengers
Airbag unit (SDM)
Drivers
Front seat
Fixed type buckle
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Belt type buckle
Drivers airbag
BODY INTERIOR
STAVIC - 2004.09
5A
Pretensioner
Retractor
Swivel seat (Rear 1st seat)
Rear 3rd seat
Rear 1st seat

BODY INTERIOR
STAVIC - 2004.09
Rear 2nd seat
Rear 1st seat
Rear 2nd seat
Rear 3rd seat

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
AIRBAG
1. COMPONENTS
Drivers Airbag Module
Airbag module
Steering wheel
Contact coil
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
Passengers Airbag Module
Cushion
Retainer
Housing
Inflator
Bracket
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
2. FUNCTION DESCRIPTION
Bag (Cushion)
Airbag Module
The airbag system performance is influenced on the

cushion size, shape and position.
The driver airbag module is under the center pad of the

steering wheel.
The cushion strength is a important parameter on the

impact absorb effect.
The passenger airbag module is installed in the instrument panel at passenger side.
Therefore, the control of the airbag performance

depends on cushion size, shape, inflator characteristic
and vent hole size for the gas discharge.
The driver and passenger side airbag is inside each seat.
The cushions material and folding function to control

the cushion deployment direction and the performance
to protect passengers face.
Do not disassemble the airbag module because

unintentional deployment of the airbags resulting from
any damage or interference of the module can cause
injury.
[Notice]
Module Cover/Housing
It is a type of a container that includes the cushion
and the inflator.
The module housing functions to deliver the reaction
force between the body structure and the airbag (The
airbag reaction is absorbed generally to the steering
wheel or instrument panel).
The module cover must be considered in a viewpoint
of protection between exterior, internal units and
cushion. Also the module cover should be designed
not to cause any personal injury for deployment.
Inflator
The inflator is a type of the direct gas generated device.
The inflator with initial low pressure provides negative
restraint effect regarding passengers moving and time.
On the contrary, the inflator with initial high pressure
allows other components of the airbag to make a
excessive impact resulting in any personal injury.
Thus, the inflator output must be optimized according
to the characteristic of the vehicle and passenger
moving.
The discharge gas has no toxicity or inflammability
and also it is the important parameter to control the
high temperature for gas firing.
SDM (Sensing and Diagnostic

Module)
1. The airbag system consists of the module section
(driver, passenger and side), seat belt section and
SDM.
2. The SDM has no user-serviceable parts and monitors
the system components continuously. The SDM also
records any faults which are discovered.
3. The SDM allows the fault codes to be retrieved with a
scan tool and illuminates a warning lamp that alerts
the driver to any faults.
The SDM located on floor beneath the floor console
assembly. The SDM performs the following functions:
Impact decision processor function.
Determine the airbag deployment through the impact
signal of the accelerometer sensor and the safety
sensor.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
Malfunction detection and recording any faults that
are detected.
Monitor the supplemental restrain system electrical
components and set a diagnostic trouble code when
malfunction is detected.
Contact Coil
The contact coil is installed between the steering wheel
and the steering column and contains a coil that enables
to contact electrically between the airbag wiring harness,
the driver airbag module and the horn switch.
Display airbag fault codes

Display airbag fault codes and system status
information when connected to a scan tool.
Self-diagnosis function
Illuminate the AIRBAG indicator to alert the driver to
any fault.
[Notice]
Turning the steering wheel more than three and onequarter turns may damage the clock spring. The contact
coil should never be disassembled and must be replaced
if the airbag have been deployed.
Power supply function

Provide a reserve power source to deploy the airbags
and pretensioners if an accident has disabled the
normal power source.
Accelometer Sensor
The accelerometer sensor electronically represents the
acceleration or deceleration of the vehicle during a frontal
impact.
In this electronic representation, the electrical signal is
proportional to the acceleration or deceleration of the
vehicle.
Safety Sensor
The safety sensor is safety device made up of a dualcontact, electro-mechanical switch that:
1. Acts independently of the electronic components.
2. Connects the acceleration sensor in series in order
to make up for the weak points in the current
electronic sensor.
[Notice]
Turn the label of the clock spring clockwise to lock and
turn the label of the clock spring counterclockwise
approximately 2.9 0.2 turns to the neutral positions
with the front wheels ahead.
Align the pointed marks 43 .
Micro Controller
This device receives the impact signal from the sensor for
vehicle impact and identifies whether the current condition is necessary for airbag deployment or not. And then
the controller sends the specified currents to the airbag
ignition circuit as needed.
This device always monitors the airbag system in conduction with the diagnostic circuit. When it is detected
any problem, it illuminates the airbag warning indicator to
inform driver of the fault and stores the fault information.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
Airbag Warning Lamp

The instrument cluster contains an airbag warning indicator bulb to verify the operation of the AIRBAG indicator
and sensing and diagnostic module (SDM).
The SDM performs a turn-on test when the ignition is turned
ON. The SDM flashes the AIRBAG indicator seven tomes
by supplying an intermittent ground to the indicator lamp
circuit. After flashing seven times, the AIRBAG indicator
will turn off if no more malfunctions have been detected.
Wiring Harness Connectors

If the sensing and diagnostic module (SDM) electrical connector is not attached properly, a built in shorting bar will
connect the wire from airbag warning lamp with the SDM
ground wire. This turns on the AIRBAG indicator.
To prevent deployment during servicing, additional shorting bars are located in following locations:
Driver airbag module connector
Passenger airbag module connector
Driver and passenger side airbag module connector
SDM wiring harness connector
Contact coil connector to airbag wiring harness
The shorting bar is only a backup safety device. Always
disable the supplemental restraints system (SRS) before
beginning any service procedure.
Belt Pretensioner
The belt pretensioner enables to retract the driver and the
passenger seat belt webbing to reduce any personal impact when accounted a frontal collision.
Warning Lamp Status
Fault Contents
Flash seven times within 7

seconds and then turn off
System OK
Warning lamp stays ON
System fault
Internal SDM fault
No turn on
Power supply circuit open

and fuse open
Warning lamp circuit open
SDM fault
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
3. INFLATION OF AIRBAG
Front Airbag Operation (Drivers and Passengers)

The air bag inflates when:
Frontal impact against a solid concrete wall at over 25 km/h or near-frontal impact within 30 degrees from the center
of the vehicle at both corners
The air bag can inflate when:
Underbody impact from the road surface; impact against the curb at a very high speed; dropping impact onto the
road surface with a large angle
The air bag does not inflate when:
Rollover, side impact or rear impact
The air bag seldom inflates when:
Oblique impact, rollover
Weak impact in which the sensor is unable to detect (under the inflation requirements)
Impact against narrow objects such as a telegraph pole or a tree
The vehicle falls into a drainage or a puddle
The front of the vehicle crashes into high impact point vehicle such as a truck
Impact on the hood by falling stones
The air bag warning lamp is on
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
10
4. AIRBAG UNIT (SDM)

System Layout
Drivers
airbag
Passengers
airbag
Airbag unit
Drivers seat
Passengers seat
SDM Specification
Item
Specification
Voltage range
9 ~ 16V
Temperature range
-30 ~ 85C
Accelometer dynamic sensing range
-50 ~ 50G
Impact record
Diagnostic trouble code
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
11
5. WIRING DIAGRAM
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
12
Possible Cause
Ignition ON
Check warning
lamp on I/P
Action
Does the warning lamp blink

at seven times for 7 seconds and then turn off?
Yes
System OK
No
Connect the scan tool to diagnostic connector (ALDL).
Does the fault code display

on the scan tool display?
Yes
Perform Diagnostic System Check.
No
Check any fuse open.
Select the fault code display menu and clear code menu.
Replace fuse.
Is there any open in fuse?
Is there any short in fuse?
Yes
Disconnect wiring connector.
No
Check any wiring short between fuse and wiring connector.
Yes
Repair wiring.
No
Disconnect SDM wiring connector.

Check wiring short between connector terminal and SDM
connector terminal.
Is there any short in wiring?
Is there any open in wiring?
Yes
Replace airbag wiring.
No
Check any open between ALDL connector No.4, No.5 terminal and ground.
Yes
Repair wiring
No
Ignition ON
Measure voltage at the cigar lighter socket.
Does the voltage indicate 11

~ 14 V?
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Yes
Check any open or short between ALDL connector terminal

and wiring connector terminal.
No
Repair the wiring of the cigar lighter socket.
Is there any open or short

in wiring?
Yes
Repair wiring
No
Check any open or short between SDM connector terminal

and wiring connector terminal.
Is there any open or short

in wiring?
Yes
Replace the airbag wiring.
No
Replace the SDM.
BODY INTERIOR
STAVIC - 2004.09
5A
13
Diagnostic Trouble Code

Code
1101
Fault Contents
High battery voltage
Check
Check the alternator voltage
Check the battery
Check the airbag unit terminal
1102
Low battery voltage
Check the alternator voltage

Check the battery
Check the airbag unit terminal
1346
Drivers air bag circuit resistance too low
Check the connection of the driver airbag connector.

Check the wiring condition of the driver airbag.
(including clock spring)
Check the bending of the airbag terminal.
1347
Drivers airbag circuit short to battery voltage

1348
Drivers airbag circuit short to ground

1349
Drivers airbag circuit short to battery voltage

1352
Passengers airbag circuit resistance too high
Check the connection of the passenger airbag connector.

Check the wiring condition of the passenger airbag.
1353
Passengers airbag circuit resistance too low

1354
Passengers airbag circuit short to ground

1355
Passengers airbag circuit short to battery

voltage

1361
Drivers pretensioner circuit resistance too

high
Check the connection of the driver pretensioner connector.

Check the wiring condition of the driver pretensioner.
1362
Drivers pretensioner circuit resistance too low

BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
14
Code
Fault Contents
1363
Drivers pretensioner circuit short to ground
Check
1364
Drivers pretensioner circuit short to battery voltage

1367
Passenger pretensioner circuit, resistance too high
Check the connection of the passenger pretensioner connector.

Check the wiring condition of the passenger pretensioner.
Passenger pretensioner circuit, resistance too low
1368

Passenger pretensioner circuit, short to

ground
1369

Passenger pretensioner circuit, short to

battery voltage
1370

1620
SDM interal fault
Replace the SDM
1650
Front impact memorid
Replace the SDM
1651
Side impact (driver) memoried
Replace the SDM
1652
Side impact (passenger) memoried
Replace the SDM
1657
Belt pretensioner operation memoried
Replace the SDM
1670
Secondary front impact memoried
Replace the SDM
2500
Warning is faulty
Check the wiring to warning lamp

Check the warning lamp bulb
Check the SDM unit terminal
[Notice]
Use only the scan tool to check the airbag module and the sensing and diagnostic module (SDM). Never measure the
resistance of an airbag module with an ohmmeter. An ohmmeters battery can deploy the airbag and cause injury.
Before testing, disconnect the negative battery cable. Wait 1 minute for the SDM capacitor to discharge. The capacitor
supplies reserve power to deploy the airbags, even if the battery is disconnected. Unintentional deployment of the
airbags can cause injury.
Do not attempt to repair the supplemental inflatable restraints (SIR) wiring harness. An SIR repair can create a highresistance connection which can keep the airbags from deploying when needed, resulting in injury.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
15

Scanner
BODY INTERIOR
STAVIC - 2004.09
Wheel wrench
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
16

Airbag Module(Drivers Airbag)
Preceding Work: Disconnect the battery negative cable.
1. Align the steering wheel and remove airbag module mounting bolts.
2. Disconnect airbag module and horn connector, and then remove the module from steering wheel.

[Notice]
Pay attention to the connection of airbag module and its
mounting position.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
17
Contact Coil
1. Remove horn, airbag module, steering wheel(1), and lower
panel(2) from steering column.
2. Remove the steering column upper & lower cover.
3. Unscrew the contact coil mounting bolts and remove it from the steering column.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
18
Tightening torque
10 1.0 Nm
[Notice]
Allgn the contact coil to the right direction. (Refer to the arroow mark in the following picture)
If thealignment of contact coil, is not precise. It could result in a accident due to bad steering condition.
Also, it can damage a contact coil and therefore, can be a reason of airbag failure.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
19
Passengers Airbag
2. Remove the I/P panel.
3. Remove the supplementary airbag module.

BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
20
Airbag Unit (SDM)

Preceding Work: Remove the center facia
1. Remove the center floor duct.
2. Disconnect the SDM and ground connectors.

3. Remove the SDM from the mounting deck.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
21
SEAT BELT
1. COMPONENTS
11 Passengers
Front Seat Belt (3 point)
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point + 2 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 3rd row (3 point + 2 point)

Upper anchor
Retractor
Buckle
Lower anchor
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
22
9 Passengers
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 3rd row (3 point + 2 point)

Upper anchor
Retractor
Buckle
Lower anchor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
23
7 Passengers
Height adjuster
Buckle
Pretensioner
Lower anchor
Rear 1st row (3 point)
Upper anchor
Retractor
Buckle
Lower anchor
Rear 2nd row (3 point + 2 point)

Upper anchor
Retractor
Buckle
Lower anchor
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
24
2. REMOVAL AND INSTALLATION - SEAT BELT

Seat Belt (3 point)
1) Front seat belt
1. Remove front & rear scarf trim. (screw - 6 EA)
Scarf trim
Front
Rear
2. Unscrew seat belt upper / lower anchor bolts (17 mm - 2 EA) and remove the seat belt.
Seat belt anchor

bolts
(A) Upper anchor

bolt
(B) Lower anchor

bolt
3. Disconnect the pretensioner connector and unscrew the mounting bolt
Pretensioner
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
25
2) Rear 1st / 2nd / 3rd seat belt

1. Unscrew seat belt upper / lower mounting bolts.
Rear 3rd seat belt
Rear 2nd
seat belt
Rear 1st seat belt
[Notice]
To remove rear 3rd row seat belt, remove the seat from vehicle first.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
26
2. Unscrew the retractor mounting bolts to remove seat belt assembly.
Rear 1st row

seat belt
Rear 2nd row
seat belt
Rear 3rd row
seat belt
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
27
Seat Belt (2 point)

1) Rear 1st seat belt
1. Unscrew seat mounting bolts and remove the seat.
[Reference]
2-point type seat belt are installed at the center seat of rear 1st / 2nd / 3rd row seat.
Rear 1st seat have two types of seat belt. Normally it adapts 3 point type, however, it adapts 2 point type seat belt when
swivle.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
5A
2. Unscrew the retractor mounting bolt to remove seat belt assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
29
Center Seat Belt

1. Disassemble the seat mounting part on the seat under
cover.
2. Unscrew the seat mounting bolt and remove it.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
30
Buckle
1. Fixed type buckle
Preceding Work: Removal of the seat assembly
1. Remove seat cover.
2. Unscrew the mounting bolt and remove the buckle.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
31
2. Belt type buckle

Preceding Work: Removal of the seat assembly
1. Disconnect the seat connecting cable and unscrew the
seat back mounting bolt to remove it.
2. Remove screws on the seat and pull away the seat cloth.
3. Unscrew the buckle mounting bolt and remove the buckle.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
32
SEAT
1. COMPONENTS
Seat control switch

Seat height control
Reclining control
Seat position control
Sliding control
Sliding adjust lever
Seat warmer switch
Back flat adjust lever
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Back supporter (Drivers seat)
BODY INTERIOR
STAVIC - 2004.09
5A
33
Head rest
Back folding adjust lever
Rear 3rd seat back folding adjust lever
Seat swivel control lever
Seat sliding adjust lever
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
34
2. SEAT LAYOUT
Layout - 11 Passengers
Front seat : Move 36 mm from the far

end to the front
Rear 1st seat : Movable
Rear 2nd seat: Movable
Rear 3rd seat : Fixed
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
35

end to the front
Rear 1st seat : Movable
Rear 2nd seat: Movable
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
36
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
37
Various Seat Arrangement

Front seat & rear 1st seat : Semi full flat
Front seat : Move to the far front

Back semi full flat
Rear 1st seat : Move to the far end
Rear 2nd seat: Move to the far end
Rear 1st & 2nd seat full flat

end to the front
Rear 1st seat : Move to the far front
Remove head rest
Back full flat
Back semi full flat
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
38
Rear 1st seat (when swiveled)

Center seat jumping
Swiveled
Rear 1st swiveled and rear 2nd seat back folding while driving

Center seat jumping
Swiveled
Back folding
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
39
Rear 1st seat swiveled and rear 2nd seat back folding (while parking)
Front seat : Move to the far front

Rear 1st seat : Middle
Center seat jumping
Swiveled
Rear 2nd seat: Middle / Back folding
8 passengers with loading

end to the front
Rear 1st seat : Middle
Rear 2nd seat: Middle
Rear 3rd seat : Double folding
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
40

end to the front
Rear 2nd seat: Middle
Rear 3rd seat : Double folding
Front seat : Move to the far end /

Back folding
Rear 1st seat : Middle / Back folding
Rear 2nd seat: Middle / Back folding
Rear 3rd seat : Middle / Back folding
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
41
Entry Way
Rear 1st seat : Folding center seat

Rear 2nd seat : Folding center seat
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
42
Sliding of Rear 1st and 2nd Seat
- 4 rail (1.610mm) for rear 1st and 2nd seat sliding

- Rail mounting : Floor bolt type
Seat
Sliding distance
Seat
Sliding distance
Front
228 mm
Rear 3rd
Fixed
Rear 1st
280 mm
Rail overlength
1,610 mm
Rear 2nd
400 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
43
Front
Seat
Rear 1st
seat
Rear 2nd
seat
Rear 3rd
seat
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
44
Seat Mounting Point
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
45
Removable Seat
1. Fold down the seatback of the third row seat while puling
up the seatback reclining lever ( ).
2. Remove the seat rail covers (
3. Slide the third row seat to its rear end (arrow direction)
while pulling up the seat sliding lever ( ).
4. Carefully remove the third row seat from the rail by using
the hand grips ( ,
) on the seat as shown in the
figure.
5. Install the seat in the reverse order of removal.
[Caution]
Be careful not to drop the seat when removing it. It may
cause a personal injury.
Make sure that the seat is securely engaged on the rail
during installation.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
46
4. OPERATION OF SEAT
Front Seat (Drivers Seat)
1) Components
Seat warmer
connector
Seat position
(up/down motor)
Seat position
(front up/down
rail)
Seat position
(up/down rail)
Sliding rail
Seat position
(rear up/down
motor)
Sliding motor
Reclining motor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
47
2) Operation of seat
Sliding
: Seat moves from front to rear controllde
by sliding control switch
Seat position (front up/down)

: Front side of seat moves up/down
controlled by seat position control
switch
Seat position (rear up/down)

: Rear side of seat moves up/down
controlled by seat position control
switch
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
48
Seat height (up/down)

: Seat moves up/down controlled
by seat height control switch
Seat reclining motor
Reclining
: Seat back reclining controlled by
seat reclining control switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
49
3) Seat electrical equipment check
Disconnect the seat wiring connector and check if the power is supplied (Refer to the wiring diagram)
1) If the power supply has no problem, remove the seat.
2) Check the motor and wiring if damaged.
3) Connect the battery to the seat connector.
4) Control the seat switch and check the opration.
[Notice]
Electrical parts are not supplied by a part separately.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
50
5A
4) Operation of center seat

When seating
When jumping
- Pull up the center seat when to jump

- Push down the center seat when to seat
5) Removal and installation of center seat (jumping seat)
- Unscrew 4 mounting nuts to remove the center seat
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
51
Rear Seat
1) Rear 1st seat (swivel seat)
Seat back folding cable
Seat back flat cable
Jumping
mechanism
Sliding cable
Sliding lever
Swivel lever
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
52
2) Operation of rear seat (Rear 1st and 2nd seat)
Seat sliding
Front
Rear
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
53
3) Seat back flat

- When to recline or to flat fully
Rear 1st
Rear 2nd
4) Seat back folding

- Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table.
Rear
1st/2nd seat
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
54
5A
5) Seat swing (Rear 1st seat)

- Turn around seat as the swing lever is pulled.
6) Rear 3rd seat

- Pull the lever behind back seat to fold the back seat.
- Pull the lever under back seat to fold up the seat
- As the seat is folded, disconnect hook and spread out the board
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
55
5. SEAT RAIL
Distance (cm)
A. Inner rail
50
B. Inner rail
74
- Outter rail
C. Outter rail

1. Remove all rear seats and then, unscrew the seat rail
guide screws.
2. Remove three screws under OVM tool storage.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
98
56
5A
3. Unscrew the rear seat belt lower anchor bolt.
4. Remove the rear carpet and unscrew the seat rail

mounting bolts.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
57
ACCESSORIES
1. STORAGES
Overhead console
Front door map pocket
Console box
Glove box
Passengers cabinet
Seat back pocket
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
58
1) Console Box
- Foot lamp and a speaker are installed.
Console box - Fixed type

Standard
CD Changer (6 EA)
DVD Changer (8 EA)
Components
1. Armrest
2. Console main rid & tray
3. Console rear facia
4. Console main rid cover
5. Rear foot lamp
6. Console main & tray
7. Console main bracket
8. CD Changer cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
59
Console box - Portable type
When Installed
When used as table
When carried out
Console box - Portable type
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
60

Console box assembly
- Unscrew bolts and nuts to remove console box.

Bolt
10 mm - 2 EA
Nut
10 mm - 2 EA
CD Changer & DVD Changer
- Unscrew the bracket bolts (10 mm - 4 EA) and remove the changer assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
61
2) Glove Box
1. Disconnect the glove box clip (1) and wire.

2. Unscrew the box mounting bolts (4 EA).
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
62
3) Overhead Console
1. Unscrew two mounting screws in the sun glass
cabinet and remove the overhead console by using a
tool.
2. Disconnect multi meter and room lamp connector.

And then, remove the console assemble.
3. Unscrew three screws behind the console assembly to remove multi meter.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
63
4) Passengers Cabinet
Above glove box

Preceding Work: Removal of glove box and I/P lower panel (passenger)
1. Open the cabinet and remove the mounting screws.
2. Unscrew the passengers cabinet mounting screws (LH / RH / center) at the back of lower panel.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
64
2. CONVINIENT DEVICES
Front cup holder
Ticket holder
Front cigar lighter
Back table
Power outlet
Rear cigar lighter
Tea table
Rear cup holder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
65
1) Front Cup Holder / Cigar Lighter / Power Outlet Assembly

Under I/P center panel
Cup holder
BODY INTERIOR
STAVIC - 2004.09
Power outlet / cigar lighter
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
5A

1. Remove cup holder mounting screws (2 EA).
2. Disconnect power outlet and cigar lighter lighter connector and remove the assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
67
2) Rear Cup Holder and Rear Cigar Lighter

Preceding Work: Removal of lower quarter trim and rear 2nd / 3rd seats.
1. Remove the trim mounting screws shown in the above

picture.
2. Disconnect the cigar lighter and remove the cup holder
assembly.
[Reference]
When to remove rear cigar lighter only, remove the lower
quarter trim and remove the cigar lighter from inside of the
trim.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
68
3) Sunvisor
Drivers
Passengers
- Unscrew the mounting screw and remove it.

- Remove the sunvisor.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
69
4) Tea Table
[Notice]
Dont put a load heavier than 3.5kg on the tea table.
Dont use the table while driving to prevent body injury.
1. Remove two upper mounting screws.

2. Remove the tea table.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
70
5) Power Seat Switch Assembly (Drivers Seat)

Preceding Work: Removal of drivers seat
1. Remove the power seat nob with a proper tool.

2. Remove seat side cover and unscrew the power seat switch unit mounting screw on the rear.
3. Disconnect the connector.
6) Back Table & Folding Lever
- Unscrew table mounting screws (4 EA).

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
71
3. ETC
1) ECM Room Mirror
1. Remove room mirror cover with a screw driver.
2. Disconnect the connector.

3. Pull the room mirror downward to disassemble.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
72
5A
2) Rain Sensing Unit

Rain sensing unit detect the rain fall and control the speed of
wiper operation. This system is operated only when the wiper
switch is put on Auto mode.
[Refer th the electrical part] of this manual.

1. Remove the unit with a tool refering the picture below.
2. Disconnect the connector and disassemble the rain

sensing unit.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
73
3) Hand Grip
Passengers Overhead
B Piller
Rear 1st & 2nd Seat

Rear 1st seat
BODY INTERIOR
STAVIC - 2004.09
Rear 2nd seat
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
74
4) Fire Extinguisher & OVM Tool

Fire Extinguisher
- Under rear 3rd seat
OVM Tool
- Under rear 3rd seat floor cover.
Components
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
75
INSTRUMENT PANEL ASSEMBLY

Preceding Work:
2. Remove all the parts shown on the picture below.
P pillar
Cluster and center cover
A pillar
Door molding
Center speaker
Center speaker
Door molding
Center console
assembly
Lower panel - passenger
Lower panel - Driver
3. Remove door molding
and A pillar cover
4. Remove the I/P panel side cover (LH/RH).

5. Remove the front center speaker
cover assembly .
, cluster and center
6. Remove the center console assembly

unit.
BODY INTERIOR
STAVIC - 2004.09
and AV head
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
76
5A
7. Remove the lower panel assembly.

1) Disconnect incar / humidity sensor, 4WD operation
switch, rear wiper switch (2).
8. Remove instrument lower panel assembly (passenger

side).
1) Remove the glove box.
2) Remove the lower inner panel.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
77

1. Disconnect all the connector at the I/P panel.
2) Passenger
1) Driver
1. Sun roof
3. Door connector, floor, seat belt pretensioner
2. Door connector, floor, seat belt pretensioner
7. GPS
16. Earth
8. Audio optic cable connector
17. Earth
9. Rear monitor
18. Earth
12. Brake connector
11. Parking connector

13. Accelator connector
14. Sensor cluster
9. Rear monitor
4. T/M controller & Earth
10. SDM connector
3. LH floor connector
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
78
3) Center
5. T/M control connector
7. Earth
8. Earth
10. SDM connector
4) ETC
12. Accelator pedal connector (A)
Aircon module connector (3 point)
13. Brake pedal connector (B)

A
11. Parking brake connector.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14. Sensor cluster
BODY INTERIOR
STAVIC - 2004.09
5A
79
2. Remove bolt and nut on the instrument panel.
* ICM Box assembly
* Drivers side I/P lower braket
(10 mm - 3 EA: Nut)
(10 mm - 2 EA:Bolt)
1. I/P side mounting bolts

(12 mm - 3 EA: LH/RH)
2. Drivers side I/P inner bolts

(12 mm - 3 EA: LH/RH)
3. Center facia lower bolts

(10 mm - 2 EA: LH/RH)
4. I/P inner side mounting bolts

(12 mm - 1 EA: LH/RH)
BODY INTERIOR
STAVIC - 2004.09
* To remove I/P panel, unscrew the steering wheel

mounting bolts (12 mm - 2 EA) and remove the wheel.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5A
80
3. Remove the following parts from the instrument panel.
1. Tweeter speaker
2. Auto light unit / 3. Sun sensor
4. GPS
5. Optical cable
6. Passengers airbag module
7. I/P wind blow nozzle housing
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY INTERIOR
STAVIC - 2004.09
5A
81
4. Remove the panel bracket from the instrument panel.
5. Remove front dust from the instrument panel.
BODY INTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
MEMO
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5B
COMPONENTS AND LOCATION

Hood
Roof rack
Front bumper assembly
Front door
BODY EXTERIOR
STAVIC - 2004.09
Rear door
Rear view mirror
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5B
Rear view camera

Rear spoiler
Tailgate
Rear bumper assembly
Sunroof assembly
Wide ganish assembly
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
DOOR SYSTEM
1. LAYOUT - FRONT DOOR
A. Inside door handle
B. Outside door handle
C. Power window switch
D. Folding switch & Adjustment

switch (Rear view mirrow)
E. Door courtesy lamp
BODY EXTERIOR
STAVIC - 2004.09
F. Door striker & contact switch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5B
Check linkage
Door hinge
Door connector
Door latch & crank
Rear view mirror folding unit
Window regulator & motor
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
2. LAYOUT - REAR DOOR
Inside handle
Twitter speaker
Door courtesy lamp
Power window switch
Door latch & crank
Door hinge
BODY EXTERIOR
STAVIC - 2004.09
Door striker
Window regulator & Motor
Contact switch
Door check linkage

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
5B
3. OPERATION - WINDOW
Window regulator
Guide rail
Regulator operating cable
Window motor
Operating Process
Power window motor (1) which is controlled by the window switch draws up and down the window regulator (2) and
operating cable. The window glass move up and down with the window regulator.
Window motor
Operating cable
Window up/down
Window regulator
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
4. OPERATION - DOOR LOCK / UNLOCK

Front Door
Connecting rod - key cylinder
Door key cylinder

Outside door handle
Lock / Unlock cable
Connecting rod - outside handle
Operating cable - Inside handle
Door latch
Lock / Unlock
Inside door handle
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Operating Process
10
5B
Operating Process
Lock / Unlock (Inside door handle)
Operation of lock button
Operating cable
Latch lock / Unlock
Inside handle
Operation of Inside handle
Operating cable
Latch open mode
Outside handle
Operation of outside handle
Connecting rod - outside handle
Latch open mode
Key cylinder
Insert key & operation
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Latch lock / Unlock

BODY EXTERIOR
STAVIC - 2004.09
5B
11
Rear Door
Outside door handle
Rock / Unlock cable
Connecting rod - Outside handle
Operating cable - Inside handle
Lock / Unlock
Inside door handle
CHILD / SAFETY mode
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
12
5B
Operating Process
Lock / Unlock (Inside door handle)
Lock button
Operating cable
Latch lock / Unlock
Inside handle
Operation of handle
Operating cable
Open mode - Latch
CHILD / SAFETY mode
Safety (FREE) mode
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
Latch & Crank in operation
BODY EXTERIOR
STAVIC - 2004.09
5B
13

Front Door Assembly
Preceding Work: Disassembly of battery cable (-)
1. Door connector
2. Door check link
3. Door hinge
1. Disconnect the door connector (1).

2. Unscrew the check linkage bolt (2) at body side.
3. Unscrew the upper and the lower door hinge bolts (3).
4. Remove the door assembly.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
14
5B
Front Door Trim

Preceding Work: Disassembly of battery terminal (-)
1. Remove five screw rivets at the lower door trim.
2. Remove armrest grip cover and two screws.
3. Remove door handle cover.

4. Remove one screw (Refer to arrow mark).
[Notice]
Disconnect door handle cover with slim tool(driver) from
down side first otherwise, the grip holder can be damaged.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
15
5. After getting some space (1), disassemble door trim from the door panel as pushing up (2).
6. Remove door courtesy lamp connector & outside mirror connector at the inside of door trim.
7. Disconnect the power window switch.
8. Disassemble the front door trim.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
16
5B
Front Door Trim Seal

Preceding Work: Removal of door trim
1. Remove door handle screw (1) and disconnect door handle

cable.
2. Unscrew 4-screws of two brackets.
3. Be careful not to damage the seal.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
17
Window Regulator Assembly

1. Unscrew two mounting bolts and disassemble door window
[Notice]
Be careful not to damage the body coating by window glass.
2. Be careful not to damage the body coating by window glass.

3. Disconnect door window regulator and motor mounting nuts (6 mm - 7 EA).
4. Disassemble window regulator assembly.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
5B
Window Motor (Front / Rear)

Preceding Work: Disassemble of window regulator & motor assembly
- Disassemble power window motor mounting bolts (10 mm ~ 3 EA) from the requlator.
Door Latch & Crank Assembly

1. Disconnect key cylinder rod (1), outside handle rod (2) and rear view mirror folding unit connector.
2. Disconnect latch and crank assembly with mounting nuts (Hex - 3 EA).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
19
Rear Lock Striker (Front / Rear)

1. Removal :
1) Disassemble door lock striker with two bolts
2. Installation :
1) Temporarily install door lock striker.
2) Adjust the location of door lock striker and fully
tighten the bolts.
Tightening torque
20 ~ 28 Nm
Door Lock Striker Adjustment

1. Removal :
1) Disassemble door lock striker with two bolts
2. Installation :
1) Temporarily install door lock striker.
2) Adjust the location of door lock striker and fully
tighten the bolts.
Tightening torque
20 ~ 28 Nm
[Notice]
The door lock striker is an important attaching part that can affect the performance of vital components and systems and
can cause major repair expenses. If replacement becomes necessary, the door lock striker must be replaced by one with the
same part number or with an equivalent part. Do not use a replacement part of lesser quality or of a substitute design. The
specified torque values must be used during reassembly in order to ensure the proper retention of the part.
The door lock striker consists of a striker with two screws that are threaded into a tapped, floating cage plate located in
the appropriate body pillar. This floating cage plate allows the striker to be easily adjusted in or out and up or down. The
door is secured in the closed position when the door lock fork snaps over and engages the striker.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
20
5B
Inside Door Handle

1. Disconnect connecting rod-key cylinder (1) and connecting rod - outside rod handle.
2. Disassemble outside handle assembly (6 mm - 3 EA).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
21
Front Door Speaker

- Disconnect the door speaker connector (4 bolts)
Drivers side
Passengers side
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
22
5B
Front Door Speaker

- Unscrew 6 bolts to remove door armest grip.
Rear View Mirror Folding Switch

Preceding Work: Removal of door armrest grip
Adjust switch - Rear view mirror
Folding switch - Rear view mirror
- Disassemble adjustment & folding switch assembly (Rear view mirrow)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
23
Door Courtesy Lamp

- Disconnect three clip behind lamp for disassembly (Use driver)
Power Window Switch Assembly

- Disconnect three clip behind lamp for disassembly (Use driver)

BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
24
5B
Door Trim Molding

- Unscrew 7 - mounting screw to disassemble the molding.
Door Armrest Grip (II)
- Unscrew three mounting screws to disassemble door armrest grip
Door Contact Switch
- Remove a screw and disconnet door contact switch.

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
25
Rear Door Assemble

Preceding Work: Disassemble the battery cable (-)
1. Door connector
2. Door check linkage
3. Door hinge
1. Disassemble B - pillar cover and disconnect door connector.

2. Remove check linkage mounting bolt from inside.
3. Remove door hinge mounting bolts.
4. Uninstall door assembly.
5. Install in the reverse of removal.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
26
5B
Rear Window Regulator / Glass Run

1. Remove upper guide channel with two bolts, as weather strip is pulled.
2. Remove two screws in carrier plate and disassemble the window glass.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
27
3. Disassemble lower guide channel (two nuts).
4. Remove window regulator & motor mounting nuts (6 mm

- 7 EA)
5. Disconnect power window motor connector.
6. Disassemble power window regulator & window motor

assemble.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
28
5B
Door Latch & Crank Assembly - Rear

1. Disconnect handle rod - outside door (B) and power window unit connector (A)
2. Remove three nuts (C) to disassemble latch & crank assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
29
Outside Door Handle - Rear

1. Disconnect handle rod - outside handle.
2. Remove three nuts (6 mm - 3 EA).
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
30
5B
Rear View Mirror

General information
Mirror adjustment
When switch-rear view mirror is operated, two motors which of one moves up and down and the other one moves left
and right are shifted to the direction the driver intended (Refer to the picture below).
Folding
Motor is operated to fold the rear view mirrow when switch is pushed.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
31
Removal and installation
1. Remove mirror cover and three mounting screws.

[Notice]
Pull out the mirror cover as lifted upward.
2. Disconnect the connector and disassemble the outside mirror assembly.

[Notice]
Be careful not to damage the mounting fastenr guided from inside of the door when handle the mirror.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
32
5B
HOOD / BUMPER & TAILGATE

1. OPERATION - TAILGATE
Tailgate handle
Connecting - tailgate handle
Actuator
Key cylinder
Connecting rod - actuator handle

Door latch
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
33
2. LAYOUT - TAILGATE
Washer nozzle
Wipre & motor
BODY EXTERIOR
STAVIC - 2004.09
Rear view camera
Rear spoiler
Key cylinder
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
34
Door latch
5B
Shock absorber
Door hinge
Door striker
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
35

Tailgate Assembly
1. Remove tailgate upper & lower trim
2. Disconnect tailgate wiring & connector.
Tailgate main wiring

BODY EXTERIOR
STAVIC - 2004.09
Rear view camera / HMSL
Heating wire & Ground

CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
36
5B
3. Disconnect tailgate washer hose.

4. Disassemble tailgate assembly after remove shock absorber bolts & hinge.
5. Remove hinge cover mounting nut (M6).
6. Remove tailgate hinge mounting nut (M8) frominside.
7. Disassemble tailgate assembly.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
37
Rear Spoiler
1. Remove upper trim - tailgate.
2. Disconnect rear view camera & HMSL (High Mounted Stop Lamp) connector (B).
3. Unscrew spoiler mounting nut (4EA).
1.
2. "B"
3. "A"
4. Disasemble rear spoiler.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
38
5B
HMSL (High Mounted Stop Lamp)

Preceding Work: Disassembly of rear spoiler
1. Disassembly HMSL cover carefully with slip driver (-).
2. Unscrew two bolts to disassemble HMSL.
Components - Rear Spoiler
Connector
Rear spoiler
Bulb
Rear view carmera
HMSL
HMSL cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
39
Tailgate Trim
* Inner side view
1. Unscrew two bolts to remove upper trim - tailgate.

2. Unscrew 6 screws to remove lower trim - tailgate.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
40
5B
Wiper & Wiper Motor

Preceding Work: Removal of tailgate trim
1. Unscrew one nut (1) to remove wiper assembly (2) and unwind one mounting nut (3).
2. Disconnect motor connector and disassemble wiper motor assembly with two bolts.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
41
Latch
Latchand
andAcuator
Acuator- -Tailgate
Tailgate
Latch - Tailgate
1. Disconnect latch wiring connector (1) and connecting rod
(2) at the inside of the door.
2. Unscrew latch mounting nut (6 mm - 3 EA).
Actuator - Tailgate
1. Disconnect connecting rod at the inside of the tailgate.
2. Unscrew mounting nut (6 mm -2 EA).
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
42
5B
3. LAYOUT - COWL ASSY / HOOD
Cowl assembly
Hinge
Cap
Screw
Screw cap
Peace
Hood
Hood seal
- rear
Hinge
Bumper
Hood insulator
Hood over slam

Hood seal - sub
Hood latch handle
Hood seal - Front
Nut
Braket
Cable
Bolt
Hood latch
Key
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
43

Hood
Preceding Work: Wrap the body with soft material to prevent from damage
1. Unscrew hood hinge bolts (8 mm - 4ea) and disassemble hood from thevehicle (A).
Adjustment
1. Release the hinge bolts.
2. Have the hood mounted properly.
BODY EXTERIOR
STAVIC - 2004.09
3. Adjust the height of hood with overslam bumper.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
44
5B
Hood Latch, Cable

Preceding Work: Removal of front bumper assembly (Including head lamp)
1. Disconnect the hood cable from head latch handle.
2. Unscrew hood latch mounting bolts (6 mm - 4EA) and disconnect spring hood cable to disassemble hood latch.
3. Disassemble the hood cable.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
45
Cowl Grill & Insulator

Cowl Grill
1. Disconnect washer hoses at both wiper.
2. Unscrew wiper mounting nuts (14mm - 2EA) and
3. Remove cowl mounting clip (6EA) and screw (4EA).
4. Disassemble left / right cowl grill (Left side first, disassemble washer hose before take the cowl out)
Left
BODY EXTERIOR
STAVIC - 2004.09
Right
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
46
5B
Replacement of Hood Insulation Pad

1. Disconnet the insulation pad with 14 screws.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
47
4. LAYOUT - FRONT BUMPER
Shock absorber - Energy
Upper cover
Bolt
Bracket - side
Bumper facia assembly

Bracket - front guide bar
Nut
Bolt
Bracket - side
Front guide
BODY EXTERIOR
STAVIC - 2004.09
Fog lamp cover
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
48
5B

Preceding Work: Disconnect the battery negative cable
(1) Disassemble head lamp
(2) Disconnect fog lamp connectors
(3) Remove guide bumper with mounting bolts

(8mm x 4ea)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
49
2. Uninstall the bumper assembly
(1) Bumper mounting bolts (Upper cover side - 4EA)
(2) Bumper mounting bolts (Head lamp side)
(3) Bumper mounting bolts (Wheel arch side)
(4) Upper cover grommet screws.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
50
5B
3. Uninstall bumper facia end shock absorber - Energy
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
51
5. LAYOUT - REAR BUMPER
Bracket - Rear bumper
Mounting screw
Mounting Grommet screw
Shock absorber - Energy
Guide cover - Rear bumper
Bumper facia assembly
Bolt
PAS (Parking Aid Sensor)
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
52
5B
Rear Bumper Assembly

1. Uninstall 4 items below.
(1) Uninstall rear combi lamp
(2) Uninstall extension panel from inside to out side

carefully
(3) Remove mounting grommet screws
(4) Remove mud guard / wheel arch mounting screws
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
53
2. Disconnect parking aid sensor (3ea) inside of bumper assembly and unscrew mounting bolts to disassemble the
bumper assembly.
3. Disassemble bumper facia and shock absorber - Energy from bumper assembly.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
54
5B
KEY CYLINDER
1. COMPONENTS
Door handle - Front
Key cylinder
Starting key cylinder & key
Key cylinder - Tailgate
Key cylinder
Door handle - Front
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
55

Door Key - Front
Preceding Work: Removal of door trim / door handle - outside
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
56
5B
Tailgate Key
Preceding Work: Removal of failgate trim, seal
1. Disconnect connecting rod from key cylinder.
Connector
2. Unscrew center garnish mounting nuts.

3. Disconnect lamp-license plate connector.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
57
3. Remove the center garnish.
4. Remove two mounting bolts and key cylinder assembly.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
58
5B
SUN ROOF
1. LAYOUT - SUN ROOF
Drain hose (Front)
Drain hose (Rear)
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
59
Seal - glass panel

Glass
Glass panel
Wind deflector
Side cover - outter
Side cover - inner
Drain channel
support bar RH
Drain channel
support bar pin
Sunshade assembly
Drain channel
support
Panel
curve on
Riret roll
Return spring
Ventilation roof
Front lever
spring
Drain lever
Slider LH
Front
lever LH
Drain lever LH
Main lever LH
Retraction
bar
Pin
Breed nail
Prain channel
Frame assembly
Seal - drive tube
Tube cable guide

Frame assembly
Drive tube
Sunroof motor
BODY EXTERIOR
STAVIC - 2004.09
Sunroof control unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
60
5B

1. Drain hose
4. Control unit
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
2. Control switch
3. Sun shade & glass
5. Sun roof motor
BODY EXTERIOR
STAVIC - 2004.09
5B
61
3. OPERATION
Tilting
Motor actuates the

operating cable
Push the front side of the button when the

glass is closed then, mtor actuate the operating cable to lift up the glass. Push the
rear side of the button to put down the glass.
Mechanical equipment lifts up & down

the glass
Sliding
Motor actuates the

operating cable
push the rear side of the button
to slide the door back.
Mechanical equipment slides the

glass back and forth
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
62
5B

Preceding Work: Removal of head lining
1. Disassemble four sun roof drain hose (A).

2. Disconnect sun roof control unit connector (B).
3. Remove sun roof mounting bolts (Refer to arrow mark).
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
63
Replacement of Sun Roof Glass
- Remove 6 screws to disassemble sun roof glass.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
64
5B
ACESSORIES
1. ROOF RACK
Front / Rear mounting
Center mounting

Preceding Work: Removal of head lining
1. Remove 10 bolts (left / right 5 each), and disassemble
roof rack assembly.
2. Installations reverse order of removal.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5B
65
2. FUEL FILLER CAP CABLE

Removal and installation
Preceding Work: Removal of front seat / 2nd, 3rd raw seat / scuff trim / lower trim - B pillar /
lower trim - quarter
1. Remove lever mounting screw and cover.
2. Disassemble rear speaker - LH.

3. Press the cable holder by both side key (Refer to arrow mark) and push.
4. Disconnect the cable from cable mounting bracket.
BODY EXTERIOR
STAVIC - 2004.09
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
66
5B
3. BODY JACK POINT
* Rear
* Front
[Notice]
Be sure to lift the vehicle only on the deginated jack point otherwise, the vehicle could be body damaged.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
BODY EXTERIOR
STAVIC - 2004.09
5C
BODY COMPONENTS & DISASSEMBLY

1. GENERAL OVERVIEW
Hood & Engine Room
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
5C
Floor Panel Assembly
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
Side Panel & Rear Wheel House Panel
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
5C
Roof Panel/Tailgate/Door Panel
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
2. SIDE GARNISH
A. Wide Garnish
<Wide garnish mounted>
Door wheel arch garnish
Front wheel arch garnish
Rear door wide garnish
Rear step seal garnish
Front door wide garnish
Front step seal garnish
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
5C
B. Narrow Garnish
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
BODY DIMENSION
1. EXTERIOR
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
10
2. BODY STRUCTURE
5C
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
11
3. SIDE STRUCTURE
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
12
5C
4. WIND SHIELD
.6
1500
1563.2
15
63
.2
1321
.2
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
13
5. TAILGATE
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
14
5C
6. UNDER BODY I
732
850
300
930
1200
2203
1099.28
444
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
15
7. UNDER BODY II
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
16
8. FLOOR MEMBER
5C
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
17
9. FRONT SUB FRAME
(unit: mm)
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
18
10. BODY ROOF
5C
(unit: mm)
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
19
11. FRAME MOUNTING POINT

Front Sub Frame
Rear
Front
[Note]
Front/center/rear each washer is
incompatible. The other parts are
same.
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
20
5C
Rear Frame
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
21
BODY GAP & ALLOWANCE

1. FRONT
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
22
5C
No
Item
1
2
3
Gap
Allowance
Center accord
41
4.6
44
6.7
-2
45
H/LAMP
(+1.0)
(0, -0.5)
46
47
Fender ~ Head lamp
11
4.5
(+1,0)
(-1,0)
A pillar ~ Fander
43
HOOD to
10
Allowance
42
Gap
(+1.0)
(Erro < 0.5)
Item
40
Hood-outter
~ Bumper-upper
No
6.8
(1)
48
-1.5 1.0
Quad ~ Fender
Fender ~ Front door
49
50
12
51
13
52
Quad ~ A pillar
14
15
16
Front bumper
17
~ Head lamp
6.8 1.0
-1.5 1.0
18
19
20
21
22
23
Fender
24
~ Hood-outter
25
4.5 0.5
-0.5
(0, -0.5)
26
27
28
29
Fender
30
~ Front bumper
2.4 1.0
-2.0
(+1.5, -1.0)
31
32
33
34
35
36
Glass & Panel
37
38
39
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
5C
23
2. REAR
BODY REPAIR
CHANGED BY
STAVIC - 2004.09
EFFECTIVE DATE
AFFECTED VIN
24
5C
No
No
Item
Gap
40
Panel ~ Lamp
5.5 0.5
41
Rear lamp
~ Taillamp
0.5
Item
Gap
Roof rail
10
~ Spoiler-Rear
(+1.0)
Allowance
-2 1.0
42
43
44
45
46
8
9
10
Quarter glass-side
~ Quarter glass-rear
1.9 1.0
48
~ Tailgate panel
1.0
Tailgate panel
~ Bumper
1.0
Garnish ~ Bumper
2.0
2.5
2.2
-2.0
51
15
16
17
~ Tailgate glass
Quarter glass-side
~ Tailgate panel
5 1.0
-1
20
21
Tailgate panel
~ Tailgate glass
52
+1.5, -0.7
53
5 1.0
54
55
+0, -1
56
18
19
0.8
49
12
14
0.5
Extensior cover
50
Quarter glass-rear
~ Panel
0.0
47
11
13
Tailgate gaenish
Allowance
2.3 1
Panel ~ Bumper
0.5
57
Cover ~ Bumper
58
Cover ~ Bumper
59
Panel
3.2
60
~ Fuel door
0.5
+0, -1
22
61
23
62
Quarter glass-front
-2.2
24
63
~ Rear door frame
+1, -0
+1, -0.5
25
64
26
Quarter glass-side
27
~ Rear combi
65
2.0
66
28
67
29
68
30
69
31
32
33
Combi lamp-rear
~ extension cover
2.2 1.0
Quarter glass-front
Compressed
~ Side panel
0
1.0
34
35
Combi lamp-tailgate
36
~ Tailgate
1.8
37
38
Gap
1.0
39
Panel ~ Lamp
2.0
-0.5
CHANGED BY
BODY REPAIR
EFFECTIVE DATE
STAVIC - 2004.09
AFFECTED VIN
2-2 Wiring Diagram for Power Supplies
1. POSITION OF CONNECTOR, GROUND & SPLICE PACK
Electrical Wiring Diagram
(LHD)
Wiring Diagram for Power Supplies 2-3
2. COMPONENTS LOCATION
(LHD)
3. CONNECTOR, GROUND & SPLICE PACK INFORMATION

1) CONNECTOR
Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C101 (2Pin, Colorless)
Engine Room Fuse Box - Engine
Engine Room Fuse Box
C102 (20Pin, White)
C104 (20Pin, White)
C105 (22Pin, White)
Engine Room Fuse Box - Main
C106 (18Pin, White)
C107 (14Pin, White)
C109 (16Pin, White)
C110 (16Pin, White)
Engine - Main
ABS (ESP)
C110 (7Pin, White)
Engine - Main
-ABS(ESP)
Engine - Main
PTC
C111A (12Pin, Black)
Engine - Main
C112 (1Pin, Gray)
Engine - Starter ST
RR Pre-Heating Unit
C113 (4Pin, Black)
Engine - Alternator
Alternator
C113 (2Pin, Black)
Engine - Alternator
Alternator
C114 (42Pin, Black)
Engine - Engine Control
Right Engine Room Dash PNL
C114 (42Pin, Black)
C115 (15Pin, Black)
Engine - Floor (RH)
Under the Coolant Reserve Tank
C115 (8Pin, Black)
Engine - Floor (RH)
C115A (6Pin, Black)
Engine - Floor (RH)
C116 (10Pin, Black)
Engine - FFH Control
Under the FFH
C201 (26Pin, White)
Main - Roof
Inside Parking Brake
C202 (6Pin, Black)
Main - Roof
Inside Driver Side Cowl PNL
C203 (40Pin, Gray)
Main - ICM Box
ICM Box (IP Relay Box)
C204 (20Pin, White)
Main - ICM Box
C205 (39Pin, Black)
Main - Floor (LH)
C206 (2Pin, Yellow)
W/H Air-Bag
C207 (2Pin, Black)
W/H Air-Bag
Inside Driver Under Cover
C208 (14Pin, White)
W/H Main
Inside Driver Under Cover
C209 (18Pin, White)
Main - Floor (LH)
Upper the Brake Pedal
C210 (6Pin, White)
Main - W/H Air-Bag
Behind A/V Unit
C211 (16Pin, White)
Main - W/H Air-Bag
Behind A/V Unit
C211A (13Pin, White)
W/H Air-Bag - W/H Blower
Behind Glove Box
FATC
Behind Glove Box
Manual
Connector Position
Remark
GSL
GSL
GSL
(LHD)
Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
Remark
C211B (2Pin, White)
W/H Main - W/H Air-Bag
Behind A/V Unit
C212 (4Pin, White)
W/H Main
Behind A/V Unit
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
C214 (24Pin, White)
Main - Floor (LH)
FRT TGS Lever
C216 (2Pin, Black)
W/H Air-Bag
Inside Passenger Side Cowl PNL
C217 (20Pin, Green)
Main - Floor (RH)
C218 (20Pin, Red)
Main - Floor (RH)
C219 (20Pin, Yellow)
Main - Floor (RH)
C220 (20Pin, Brown)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
C301 (4Pin, White)
Floor (LH) - Driver Seat
Under the Driver Seat
Power Seat (Seat Warmer)
C301A (2Pin, White)
W/H Drive Seat
Under the Driver Seat
C302 (4Pin, White)
Floor (RH) - Passenger Seat
Under the Passenger Seat
C303 (4Pin, White)
W/H Floor (RH)
Under the Passenger Seat
C304 (12Pin, White)
Floor (RH) - Floor (LH)
RR Left Quarter Trim
Floor (RH) - RR A/C
RR Right Quarter Trim
Dual A/C
C306 (2Pin, White)
Floor (RH)
Glass ANT
C351 (30Pin, White)
Main - Drive Door
C361 (30Pin, White)
Main - Passenger Door
C371 (11Pin, White)
Floor (LH) - RR Left Door
Under Left B Filler
C381 (11Pin, White)
Floor (RH) - RR Right Door
Under Right B Filler
C401 (14Pin, White)
Floor (LH) - Tail Gate
Left Tail Gate Trim
C402 (8Pin, White)
Upper Tail Gate Trim
RR View Camera
C402 (2Pin, White)
-AV
C901 (6Pin, Black)
Floor (LH) - Fuse Sensor
FRT Fuel Tank
C902 (12Pin. Black)
Floor (LH) - TM
T/C Left (Under the Floor)
A/T
C902 (4Pin. Black)
Floor (LH) - TM
M/T
C903 (8Pin, White)
Floor (LH) - W/H Parking Aid
Inside the Left RR Bumper
Parking Aid
C904 (16Pin, Black)
Floor (LH) - W/H EPB/EAS
Upper the RR LH Bumper
EPB/EAS
PTC
Pre-tensioner
Seat Warmer
(LHD)

2) SPLICE PACK
Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
Remark
S202 (14Pin, Black)
W/H Main
Under the Relay Box RR Left the Cluster
S203 (14Pin, Black)
W/H Main
GND
S204 (14Pin, Black)
W/H Main
Under the Relay Box RR Center the Cluster
ILL
S205 (8Pin, Black)
W/H Main
Upper the Right Driver Under Cover
CAN
S206 (14Pin, Black)
W/H Main
Inside the Left A/V Head Unit
GND
S207 (14Pin, Black)
W/H Main
Inside the Right A/V Head Unit
S301 (8Pin, Black)
W/H Floor (LH)
Beside TCU
EPB/EAS
S202
S203 (GND)
(LHD)

S204 (ILL)
S205 (CAN)
S206 (GND)
(LHD)

S207
S301 (EPB/EAS, CAN)
(LHD)

3) GROUND
Connector
Number
Connecting Wiring
Harness
Connector Position
G101
W/H Engine
Behind the Washer Tank
G102
W/H Engine
G103
W/H Engine
Behind the Air Cliner Housing
G104
W/H Engine
G105
W/H Engine
G201
W/H Main
G202
W/H Main
G203
W/H Air-bag
Beside the SDM
G204
W/H Main
Behind TGS Lever
G205
W/H Main
Beside the ENG ECU
G206
W/H Main
G207
W/H Floor (RH)
G301
W/H Floor (LH)
Under Driver Seat
G302
W/H Floor (LH)
Under Driver Seat
G303
W/H Floor (LH)
Inside the LH Quarter Trim
G304
W/H Floor (LH)
G305
W/H Floor (RH)
Inside the RH Quarter Trim
G401
W/H Tail Gate
Center the Tail Gate
G402
W/H Floor (LH)
Left the Tail Gate
G901
W/H EPB/EAS
Remark
W/H Air Bag

ECU GND
EPB/EAS
(LHD)
1. ENG ROOM FUSE BOX

1) SB1 ~ SB5
(LHD)
2) SB6 ~ SB11
(LHD)
3) Ef1 ~ Ef4
(LHD)
4) Ef5
(LHD)
5) Ef6 ~ Ef10
(LHD)
6) Ef11 ~ Ef18
(LHD)
7) Ef19 ~ Ef21
(LHD)
8) Ef22 ~ Ef26
(LHD)
2. I.P FUSE BOX

1) F1 ~ F5
(LHD)
2) F6 ~ F12
30
(LHD)
3) F13 ~ F16
(LHD)
4) F17 ~ F24
(LHD)
5 ) F25 ~ F31
(LHD)
6) F32 ~ F36
(LHD)
SECTION 5
ELECTRICAL WIRING
DIAGRAMS
TABLE OF CONTENTS
1. STARTING & CHARGING ........................................................................................... 5-4
2. PREHEATING UNIT CIRCUIT (XDI) .......................................................................... 5-6
3. ECU (ENGINE CONTROL UNIT - D27DT EU IV) ................................................... 5-8
1) ENG MAIN RELAY, PEDAL MODULE, HFM SENSOR, VALVE, ENG MOUNT .. 5-8
2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (FUEL PRESSURE,
CAM SHAFT, BOOSTER PRESSURE, CRANK SHAFT, COOLANT/FUEL TEMP.)
A/CRUISE SW CIRCUIT ....................................................................................... 5-10
3) INJECTOR, CAN LINE, STOP LAMP SW, SENSOR (A/CON, E-GAS), CLUTCH
SW ......................................................................................................................... 5-12
4. ECU (GSL G32) ......................................................................................................... 5-14
1) IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS ............... 5-14
2) O2 SENSOR, PEDAL MODULE, CRUISE CONTROL SW,
STOP LAMP SW .................................................................................................. 5-16
3) INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE .... 5-18
5. DIAGNOSIS CIRCUIT ................................................................................................ 5-20
6. TCU (5-SPEED) .......................................................................................................... 5-22
1) START MOTOR, TGS LEVER, CAN LINE .......................................................... 5-22
2) SOLENOID, OIL TEMP. SENSOR, SPEED SENSOR (N2, N3) ....................... 5-24
7. TOD ............................................................................................................................. 5-26
8. CLUSTER .................................................................................................................... 5-28
1) GAUGE(SPEED, RPM, FUEL, TEMP, WARNING LAMP(4WD, FUEL FILTER,
ABS/ESP) .............................................................................................................. 5-28
2) WARNING (EAS, EPB, TGS LEVER, AUTO PARKG) ...................................... 5-30
3) WARNING (BAT CHANGE, OIL, BRAKE ENG CHCK, AIR BAG, IMMOM SEATBELT) TURN SIGNAL, DEFOGGER, DOOR OPEN .......................................... 5-32
9. CIGAR LIGHTER, POWER OUTLET ....................................................................... 5-34
10. HEAD LAMP, DRL(DAY TIME RUNNING LIGHT) UNIT ....................................... 5-36
11. STOP, BACK UP LAMP CIRCUIT ........................................................................... 5-38

12. P.T.C (POSITIVE TEMPERATURE COEFFICIENT) HEATER .............................. 5-40
13. FATC (FULL AUTO TEMP. CONTROL) CIRCUIT ................................................ 5-42
1) CONDENSOR FAN, AIR MIX, MOTOR, SUN/WATER TEMP SENSOR ........... 5-42
2) FRT BLOWER, ACTUATOR (MODE, INTAKE), AMBIENT SENSOR ............... 5-44
3) RR AIR CON (BLOWER, MODE ACTUATOR) .................................................. 5-46
14. AIR CON (MANUAL) .................................................................................................. 5-48
1) POWER A/C, COMP., MOTOR (MODE, INTAKE, AIR MIX) ............................. 5-48
2) BLOWER MOTOR (FRT, RR) ............................................................................ 5-50
1. STARTING & CHARGING
(LHD)

A. CONNECTOR INFORMATION
Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C109 (16Pin, White)
C112 (1Pin, Black)
Engine - Starter ST
RR Pre-Heating Unit
C113 (4Pin, Black)
Engine - Alternator
Alternator
C113 (2Pin, Black)
Engine - Alternator
Alternator
C115 (15Pin, Black)
Engine - Floor (RH)
C115 (8Pin, Black)
Engine - Floor (RH)
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
C217 (20Pin, Green)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
S203 (14Pin, Black)
W/H Main
S207 (14Pin, Black)
W/H Main
G201
W/H Floor (LH)
Under Driver Seat
G302
W/H Floor (LH)
Under Driver Seat
Connector Position
Remark
GSL
GSL
Power Sheet (Warmer)

GND
B. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
(LHD)
2. PREHEATING UNIT CIRCUIT (XDi)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C102 (20Pin, White)
C104 (20Pin, White)
C105 (22Pin, White)
C115 (15Pin, Black)
Engine - Floor (RH)
C213 (15Pin, Black)
Main - Floor (LH)
FRT TGS Lever
C221 (20Pin, Gray)
Main - Floor (RH)
S205 (14Pin, Black)
W/H Main
CAN
S206 (14Pin, Black)
W/H Main
GND
S207 (14Pin, Black)
W/H Main
G102
W/H Engine
G104
W/H Engine
Connector Position
Remark
(LHD)
3. ECU (ENGINE CONTROL UNIT - D27DT EU IV)

1) ENG MAIN RELAY, PEDAL MODULE, HFM SENSOR, VALVE, ENG MOUNT
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C103 (6 Pin, Colorless)
C104 (20Pin, White)
C105 (22Pin, White)
C107 (14Pin, White)
C109 (16Pin, White)
C111A (12Pin, Black)
Engine - Main
C114 (42Pin, Black)
C115 (15Pin, Black)
Engine - Floor (RH)
C115A (6Pin, Black)
Engine - Floor (RH)
C220 (20Pin, Brown)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
S202 (14Pin, Black)
W/H Main
S203 (14Pin, Black)
W/H Main
S207 (14Pin, Black)
W/H Main
G201
W/H Main
Connector Position
Remark
GND
(LHD)

2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR (FUEL PRESSURE, CAM SHAFT,
BOOSTER PRESSURE, CRANK SHAFT, COOLANT/FUEL TEMP.) A/CRUISE SW CIRCUIT
D27DT (EU IV) ECU
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C104 (20Pin, White)
C114 (42Pin, Black)
C115 (15Pin, Black)
Engine - Floor (RH)
C220 (20Pin, Brown)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
S206 (14Pin, Black)
W/H Main
S207 (14Pin, Black)
W/H Main
G102
W/H Main
G204
W/H Main
RR TGS Lever
Connector Position
Remark
GND
(LHD)
3) INJECTOR, CAN LINE, STOP LAMP SW, SENSOR (A/CON, E-GAS), CLUTCH SW
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
C106 (18Pin, White)
C114 (42Pin, Black)
C115 (15Pin, Black)
Engine - Floor (RH)
C211 (16Pin, White)
Main - W/H Air-Bag
RR A/V Unit
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
C217 (20Pin, Green)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
G205
W/H Main
Beside the ENG ECU
Remark
ECU GND
(LHD)
4. ECU (GSL G32)

1) IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS
ECU (E32)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
C110 (16Pin, White)
Engine - Main
C114 (42Pin, Black)
C204 (20Pin, White)
Main - ICM Box
C220 (20Pin, Brown)
Main - Floor (RH)
G201
W/H Main
G205
W/H Main
Beside the ENG ECU
Remark
ABS (ESP)
GSL
ECU GND
(LHD)
2) O2 SENSOR, PEDAL MODULE, CRUISE CONTROL SW, STOP LAMP SW
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C105 (22Pin, White)
C107 (14Pin, White)
C204 (20Pin, White)
Main - ICM Box
Main - Floor (RH)
C220 (20Pin, Brown)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
S202 (14Pin, Black)
W/H Main
Under the Relay Box RR Left the cluster
S207 (14Pin, Black)
W/H Main
G201
W/H Main
G205
W/H Main
Beside the ENG ECU
Connector Position
Remark
ECU GND
(LHD)
3) INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
Remark
C104 (20Pin, White)
C106 (18Pin, White)
C107 (14Pin, White)
GSL
C114 (42Pin, Black)
GSL
C115 (8Pin, Black)
Main - Floor (RH)
C203 (40Pin, Gray)
Main - ICM Box
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
C217 (20Pin, Green)
Main - Floor (RH)
C218 (20Pin, Brown)
Main - Floor (RH)
C220 (20Pin, Brown)
Main - Floor (RH)
C901 (6Pin, Black)
Floor (LH) - Fuse Sensor
FRT Fuel Tank
S206 (14Pin, Black)
W/H Main
S207 (14Pin, Black)
W/H Main
G201
W/H Main
G203
W/H Air-bag
Beside the SDM
G301
W/H Floor (LH)
Under Driver Seat
GND
W/H Air Bag
(LHD)
5. DIAGNOSIS CIRCUIT
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C102 (20Pin, White)
C104 (20Pin, White)
C105 (22Pin, White)
C110 (16Pin, White)
Engine - Main
C115 (15Pin, Black)
Engine - Floor (RH)
C115 (8Pin, Black)
Engine - Floor (RH)
C210 (6Pin, White)
Main - W/H Air-Bag
RR A/V Unit
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
C221 (20Pin, Gray)
Main - Floor (RH)
S203 (14Pin, Black)
W/H Main
GND
S205 (14Pin, Black)
W/H Main
CAN
G201
W/H Main
Connector Position
Remark
GSL
(LHD)
6. TCU (5-SPEED)
1) START MOTOR, TGS LEVER, CAN LINE
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C104 (20Pin, White)
C105 (22Pin, White)
C112 (1Pin, Gray)
Engine - Starter ST
RR Pre-Heating Unit
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
C401 (14Pin, White)
Left Tail Gate Trim
S204 (14Pin, Black)
W/H Main
ILL
S205 (14Pin, Black)
W/H Main
CAN
G204
W/H Main
RR TGS Lever
G302
W/H Floor (LH)
Under Driver Seat
G401
W/H Tail Gate
Connector Position
Remark
(LHD)
2) SOLENOID, OIL TEMP. SENSOR, SPEED SENSOR (N2, N3)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
C902 (12Pin. Black)
Floor (LH) - TM
Under the Floor
G302
W/H Floor (LH)
Under Driver Seat
Remark
A/T
(LHD)
7. TOD
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
Remark
C105 (22Pin, White)
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
C221 (20Pin, Gray)
Main - Floor (RH)
S203 (14Pin, Black)
W/H Main
GND
S204 (14Pin, Black)
W/H Main
ILL
S205 (14Pin, Black)
W/H Main
CAN
G202
W/H Main
G204
W/H Main
Behind TGS Lever
G301
W/H Floor (LH)
Under Driver Seat
(LHD)
8. CLUSTER
1) GAUGE(SPEED, RPM, FUEL, TEMP, WARNING LAMP(4WD, FUEL FILTER, ABS/ESP)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
Remark
C105 (22Pin, White)
C204 (20Pin, White)
Main - ICM Box
C213 (22Pin, White)
Main - Floor (LH)
FRT TGS Lever
S204 (14Pin, Black)
W/H Main
ILL
S205 (14Pin, Black)
W/H Main
CAN
S206 (14Pin, Black)
W/H Main
GND
S207 (14Pin, Black)
W/H Main
G204
W/H Main
RR TGS Lever
(LHD)
2) WARNING (EAS, EPB, TGS LEVER, AUTO PARKG)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C104 (20Pin, White)
C106 (18Pin, White)
C201 (26Pin, White)
Main - Roof
Inside Parking Brake
C213 (22Pin, White)
Engine - Floor (LH)
FRT TGS Lever
C902(12Pin, Black)
Floor (LH) - TM
A/T
C902(4Pin, Black))
Floor (LH) - TM
M/T
S207 (14Pin, Black)
W/H Main
G206
W/H Main
Connector Position
Remark
(LHD)
3) WARNING (BAT CHANGE, OIL, BRAKE ENG CHCK, AIR BAG, IMMOM SEAT-BELT)
TURN SIGNAL, DEFOGGER, DOOR OPEN
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
C106 (18Pin, White)
C107 (14Pin, White)
C109 (16Pin, White)
C113 (4Pin, Black)
Engine - Alternator
Alternator
C113 (2Pin, Black)
Engine - Alternator
Alternator
C114 (42Pin, Black)
C114 (42Pin, Black)
C115 (15Pin, Black)
Engine - Floor (RH)
C115 (8Pin, Black)
Engine - Floor (RH)
C210 (6Pin, White)
Main - W/H Air-Bag
RR A/V Unit
C217 (20Pin, Green)
Main - Floor (RH)
C220 (20Pin, Brown)
Main - Floor (RH)
S206 (14Pin, Black)
W/H Main
S207 (14Pin, Black)
W/H Main
G204
W/H Main
RR TGS Lever
Remark
GSL
GSL
GSL
GND
(LHD)
9. CIGAR LIGHTER, POWER OUTLET
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
C105 (22Pin, White)
C203 (40Pin, Gray)
Main - ICM Box
CM Box (IP Relay Box)
C205 (39Pin, Black)
Main - Floor (LH)
C221 (20Pin, Gray)
Main - Floor (RH)
S204 (14Pin, Black)
W/H Main
G202
W/H Main
G204
W/H Main
RR TGS Lever
G303
W/H Floor (LH)
G305
W/H Floor (RH)
Inside the RH Quarter Trim
Remark
(LHD)
10. HEAD LAMP, DRL(DAY TIME RUNNING LIGHT) UNIT
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C104 (20Pin, White)
C105 (22Pin, White)
C107 (14Pin, White)
C109 (16Pin, White)
C204 (20Pin, White)
Main - ICM Box
C219 (20Pin, White)
Main - Floor (RH)
S206 (14Pin, Black)
W/H Main
G102
W/H Engine
G103
W/H Engine
G201
W/H Main
G204
W/H Main
RR TGS Lever
Connector Position
Remark
GND
(LHD)
11. STOP, BACK UP LAMP CIRCUIT
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
C102 (20Pin, White)

C105 (22Pin, White)
C107 (14Pin, White)
C201 (26Pin, White)
C205 (39Pin, Black)
C213 (22Pin, White)
C221 (20Pin, Gray)
C304 (12Pin, White)
C401 (14Pin, White)
C402 (8Pin, White)
C902 (2Pin. Black)
S202 (14Pin, Black)
S207 (14Pin, Black)
G303
G401

Main - Roof
Main - Floor (LH)
Main - Floor (LH)
Main - Floor (RH)
Floor (RH) - Floor (LH)
Floor (LH) - TM
W/H Main
W/H Main
W/H Floor (LH)
W/H Tail Gate

RR Parking Brake
FRT TGS Lever
RR Left Quarter Trim
Left Tail Gate Trim
T/C Left (Under the Floor )
Inside the Quarter Trim
Remark
RR View Camera
M/T
(LHD)
12. P.T.C (POSITIVE TEMPERATURE COEFFICIENT) HEATER
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C104 (20Pin, White)
C106 (18Pin, White)
Engine - Main
PTC
C115 (15Pin, Black)
Engine - Floor (RH)
PTC
C211B (2Pin, White)
RR A/V Unit
C212 (4Pin, White)
W/H Main
RR A/V Unit
C221 (20Pin, Gray)
Main - Floor (RH)
Connector Position
Remark
(LHD)
13. FATC (FULL AUTO TEMP. CONTROL) CIRCUIT

1) CONDENSOR FAN, AIR MIX, MOTOR, SUN/WATER TEMP SENSOR
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C102 (20Pin, White)

C104 (20Pin, White)
C105 (22Pin, White)
C106 (18Pin, White)
C115 (15Pin, Black)
C115 (8Pin, Black)
C203 (40Pin, Gray)
C211 (16Pin, White)
C217 (20Pin, Green)
C218 (20Pin, Red)
C221 (20Pin, Gray)
S207 (14Pin, Black)
G102
G103

Engine - Floor (RH)
Engine - Floor (RH)
Main - ICM Box
Main - W/H Air-Bag
Main - Floor (RH)
Main - Floor (RH)
Main - Floor (RH)
W/H Main
W/H Engine
W/H Engine
Connector Position
Behide A/V Unit
Behide Glove Box
Remark
DSL
GSL
FATC
Manual
(LHD)
2) FRT BLOWER, ACTUATOR (MODE, INTAKE), AMBIENT SENSOR
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C102 (20Pin, White)
C104 (20Pin, White)
C105 (22Pin, White)
C106 (18Pin, White)
C107 (14Pin, White)
C110 (16Pin, White)
Engine - Main
C211 (16Pin, White)
Main - W/H Air-Bag
RR A/V Unit
RR Glove Box
C221 (20Pin, Gray)
Main - Floor (RH)
S204 (14Pin, Black)
W/H Main
G102
W/H Engine
G104
W/H Engine
G204
W/H Main
W/H Main
Connector Position
Remark
FATC
ILL
(LHD)
3) RR AIR CON (BLOWER, MODE ACTUATOR)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
Connector Position
C105 (22Pin, White)
C107 (14Pin, White)
C201 (26Pin, White)
Main - Roof
RR Parking Brake
C211 (16Pin, White)
Main - W/H Air-Bag
RR A/V Unit
C218 (20Pin, Red)
Main - Floor (RH)
Floor (RH) - RR A/C
G201
W/H Main
G202
W/H Main
G204
W/H Main
RR TGS Lever
Remark
Dual A/C
(LHD)
14. AIR CON (MANUAL)

1) POWER A/C, COMP., MOTOR (MODE, INTAKE, AIR MIX)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C102 (20Pin, White)
C104 (20Pin, White)
C105 (22Pin, White)
C106 (18Pin, White)
C115 (15Pin, Black)
Engine - Floor (RH)
XDi
C115 (8Pin, Black)
Engine - Floor (RH)
GSL
C211 (16Pin, White)
Main - W/H Air-Bag
Behind A/V Unit
Behind RR Glove Box
C211B (2Pin, White)
Behind RR A/V Unit
C217 (20Pin, Green)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
S204 (14Pin, Black)
W/H Main
G102
W/H Air-bag
Beside the SDM
G103
W/H Main
RR TGS Lever
Connector Position
Remark
Manual
ILL
W/H Air Bag
(LHD)
2) BLOWER MOTOR (FRT, RR)
(LHD)

Connector Number
(Pin Number, Color)
Connecting Wiring
Harness
C102 (20Pin, White)
C104 (20Pin, White)
C105 (22Pin, White)
C107 (14Pin, White)
C109 (16Pin, White)
C201 (26Pin, White)
Main - Roof
Behind Parking Brake
C211 (16Pin, White)
Main - W/H Air-Bag
Behind RR A/V Unit
Behind RR Glove Box
C218 (20Pin, Red)
Main - Floor (RH)
C221 (20Pin, Gray)
Main - Floor (RH)
Floor (RH) - RR A/C
G201
W/H Main
G202
W/H Main
G204
W/H Main
W/H Main
Connector Position
Remark
FATC
Dual A/C
(LHD)

Manual de Servicio Rodius/Stavic

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Manual de Servicio Rodius/Stavic

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GASOLIN ENGINE

DESCRIPTION AND OPERATION

An automobile engine is a combination of many

Whenever valve train components are removed for

16. Engine mounting bracket

2. Intake air duct

11. Exhaust valve

4. Cylinder head cover

12. Intake manifold

19. Oil pump sprocket

13. Connecting rod

20. Oil strainer

14. Exhaust manifold

21. Oil pan

22. Drain plug

8. Spark plug connector

23. Camshaft adjuster

27. Oil pump drive chain

24. Cooling fan and viscous clutch

28. Oil return pipe

29. Timing chain

26. Flywheel of drive plate

DIAGNOSTIC INFORMATION AND PROCEDURE

Finding the Leak

Black Light and Dye Method

Repairing the Leak

4.1 Clean the area well.

The flanges or the sealing surface is warped.

4.2 Dry the area.

There are scratches, burrs or other damage to the

4.3 Operate the vehicle for several miles at normal

The gasket is damaged or worn.

COMPRESSION PRESSURE TEST

1. Compression pressure tester

Standard Service Data

Normal engine temperature

Min. 10 bar, Max. 14 bar

Optimized fuel pressure

Min. 6 bar, Max. 10 bar

Compression Pressure Tester

6. Compare the measurements of compression pressure

5. Crank the engine approx. eight revolutions by using

CYLINDER PRESSURE LEAKAGE TEST

1. Engine oil filler cap

3. Cylinder pressure leakage tester with connecting hose

Permissible Pressure Leakage

At valve and cylinder head gasket

At piston and piston ring

Cylinder Number by Mark on Vibration Damper at TDC

Bosch, EFAW 210A

9. Connect the connecting hose to tester and measure the

Replace the fuse.

Faulty spark plug.

Clean, adjust the plug gap or

Electric leakage at the high

Replace the cable.

Poor connection of the high

Replace the cable or wires.

Improper ignition timing.

Adjust the ignition timing.

Faulty ignition coil.

Replace the ignition coil.

Lock of fuel in the fuel tank.

Feed the fuel.