Daelim S1 SERVICE MANUAL

How to use this manual

This manual explains how to maintain procedure for the S2-125 manufactured by DAELIM MOTOR CO., LTD.

To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule(Section 2). Sections 1 through 2 provide information on overall vehicle; section 3, assembly and disassembly procedures for external components, and section 4 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, each page starts with disassembly and system diagrams, service information, and troubleshooting guide.

Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM Motor Co.,Ltd.,

Service Information

1

2

3

4

6

7

8

9

10

11

14

15

16

17

18

Inspections / Adjustments

External Parts

Lubrication System

5

EMS(Engine Management System)

Fuel System

Engine Removal / Installation

LH, Crank Case Cover Continuously Variable Transmission

A.C Generator / Starter Clutch

Cylinder Head / Valves

Cylinder Head / Piston

12

Transmission / Crank Shaft Crank Case

Rear Wheel / Rear Brake / Suspension / Rear Swing Arm

Charging System

Ignition System

Starter System

Lights / Switches / Horn

19

Wiring diagram

Contents

Engine

FrameElectrical

General

13

Front Wheel / Front Fork / Steering / Brake

SERVICE INFORMATION

1

1-1

1-2

SERVICE INFORMATION

1-3

1-4

SERVICE INFORMATION

1-5

SERVICE INFORMATION

1-6

SERVICE INFORMATION

1-7

SERVICE INFORMATION

1-8

SERVICE INFORMATION

1-9

SERVICE INFORMATION

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

1-10

SERVICE INFORMATION

1,965mm

743mm

1,120mm

1,350mm

770mm

126mm

127kg

277kg

60

1.75

2.25

9.6

2.2 25

80

90/70

13.8

stroke SOHC

380

AT D C

1-11

SERVICE INFORMATION

, 30A

LED

LED LED

1-12

SERVICE INFORMATION

1-13

SERVICE INFORMATION

1-14

SERVICE INFORMATION

SEAT LOCK CABLE

HORN COMP.

THROTTLE CABLE

HAZARD RELAY

HEAD LIGHT

(COUPLER)

RADIATOR ASS'Y.

BRAKE HOSE CLAMP

FR.BRAKE HOSE C

FR. BRAKE HOSE

Y

RR.BRAKE HOSE A

RR. BRAKE HOSE PIPE FR.BRAKE HOSE C THROTTLE CABLE

SEAT LOCK CABLE

FUEL BREATHER TUBE

FUEL SUPPLY TUBE

LH. RADIATOR HOSE

SIDE STAND SW.ø¨∞·∫Œ COUPLER

FUEL HOSE(TO. INJECTOR)

FUEL PUMP(TO. INJECTOR)

THROTTLE CABLE

BREATHER TUBE

BATTERY + CABLE

EARTH CABLE

ECU UNIT

FRM.EARTH CORD

SEAT LOCK CABLE

TAIL & STOP, RR. WINKER R/L REGULATE RECTIFIER

COUPLER

RR.BRAKE HOSE

START MOTOR CABLE

ACG. & CPS CORD

SIDE STAND SW.

DRAIN TUBE(AIR CLEANER)

SPEEDOMETER CABLE

SEAT LOCK CABLE

HORN COMP.

X

Z

TRUNK LAMP COUPLER

IGNITION COIL EARTH CORD

EARTH CABLE

BATTERY + CABLE

JUNCTION VALVE

RR. BRAKE HOSE PIPE

RADIATOR ASS'Y.

MAIN WIRE HARNESS

FUEL SUPPLY TUBE

FUEL BREATHER TUBE

HIGH TENSION CORD

NOISE SUPPRESSOR CAP

THROTTLE CABLE

FUEL HOSE(TO. INJECTOR)

FUEL PUMP(TO. INJECTOR)

FRAME EARTH

RH. RADIATOR HOSE

SPEEDOMETER CABLE

O2 SENSOR COUPLER

FR. BRAKE HOSE

CHARGE SOCKET COUPLER

HARNESS POSITION CLAMP

1-15

SERVICE INFORMATION

SEAT LOCK CABLE

REGULATE RECTIFIER

TAIL & STOP, RR. WINKER R/L REGULATE RECTIFIER

COUPLER

LIGHTING S/W UNIT

STARTER S/W UNIT

FUEL PUMP RELAY

RR.BRAKE HOSE

ACG. & CPS CORD START MOTOR CABLE

IGNITION COIL CORD

IGNITION COIL EARTH CORD

SPEEDO METER ASS'Y

A.P. WINKER RELAY

12V 10AH BATTERY(MF)

ECU UNIT

FRM.EARTH CORD

FUSE

O2 SENSOR COUPLER

FUEL HOSE(TO. INJECTOR)

CAN(≈ÎΩ≈øÎ) CORD

¡∂∏≥πÊ«‚¿∏∑Œ WIRING¿ª Ω«Ω√«“ ∞Õ.

HIGH TENSION CORD

START-MAG. SW. COUPLER

TRUNK LAMP COUPLER

IGNITION COIL

DIMMER S/W UNIT

WINKER S/W UNIT

HORN S/W UNIT

SIDE STAND SWICH COUPLER

THROTTLE CABLE

RH/LH RADIATOR HOSE

FUEL PUMP(TO. INJECTOR)

FUEL SUPPLY TUBE

MAIN WIRE HARNESS

FUEL BREATHER TUBE

RR. BRAKE HOSE PIPE

FR. STOP SW.

THROTTLE CABLE

SEAT LOCK CABLE

HORN COMP.

COMB. & LOCK SW.

CHARGE SOCKET

FR. BRAKE HOSE

SPEEDOMETER CABLE

RR. STOP SW. HAZARD S/W UNIT

FRAME EARTH HORN~m_? ^J`)|P~*_5 ~B_&^!`'|( ^3`!|(^!`%|3.

SPEEDO METER EARTH

HAZARD RELAY

RR.BRAKE HOSE A

HEAD LIGHT

(∞·º±øÎ COUPLER)

FR.BRAKE HOSE C

1-16

SERVICE INFORMATION

SEAT LOCK CABLE

THROTTLE CABLE

RR.BRAKE HOSE A

FUEL SUPPLY TUBE

HEAD LIGHT

(∞·º±øÎ COUPLER)

FUEL BREATHER TUBE

FR.BRAKE HOSE C

SPEEDO METER ASS'Y

A.P. WINKER RELAY

THROTTLE CABLE

FR. BRAKE HOSE

COMB.METER SOCKET

COMB. & LOCK SW.

JUNCTION VALVE

RR. BRAKE HOSE PIPE

HARNESS ~x_1~/_5 ^!`'|(^-`%|5^R`-|P CLAMP

MAIN WIRE HARNESS

VIEW Y

FR. BRAKE HOSE

THROTTLE CABLE

COMB. & LOCK SW.

VIEW X

RR.BRAKE HOSE A

SPEEDOMETER CABLE

SEAT LOCK CABLE

HORN COMP.

1-17

SERVICE INFORMATION

FUEL HOSE(TO. INJECTOR)

RR. BRAKE HOSE PIPE

MAIN WIRE HARNESS

O2 SENSOR CORD

THROTTLE CABLE

RH/LH RADIATOR HOSE

FUEL PUMP(TO. INJECTOR)

FRAME EARTH HORN~m_? ^J`)|P~*_5 ~B_&^!`'|( ^3`!|(^!`%|3.

O2 SENSOR COUPLER

BREATHER TUBE

MAPAT COUPLER

ECU UNIT

FRM.EARTH CORD

DETAIL OF O2 SENSORS PART

INJECTOR

ISA

THROTTLE CABLE

FUEL HOSE(TO. INJECTOR)

BATTERY + CABLE

START-MAGNET SW. ASS'Y.

MAIN WIRE HARNESS

ACG. & CPS CORD

START MOTOR CABLE

RR.BRAKE HOSE

TPS

VIEW Z

DETAIL OF SENSORS PART

MEMO

2-1

INSPECTIONS/ADJUSTMENTS

2

2-2

INSPECTIONS/ADJUSTMENTS

2-3

INSPECTIONS/ADJUSTMENTS

2-4

INSPECTIONS/ADJUSTMENTS

NUTS

2-5

INSPECTIONS/ADJUSTMENTS

2-6

INSPECTIONS/ADJUSTMENTS

FEELER GAUGE

COMPRESSION GAUGE

TIMINCT HOlLE CAP

COOLING FAN

ADJUST WRENCH

SPARK PLUG CAP

TAPPET ADJUST SCREW

2-7

INSPECTIONS/ADJUSTMENTS

OIL CHECK HOLE

OIL SIGHT GRASS

DRIVE FACE

DRIVE BELT

UPPER MIDDIE LOWER

UPPER MIDDLE LOWER

DRIVEN PULLEY

2-8

INSPECTIONS/ADJUSTMENTS

BRAK FLUID

Remove the brake fluid cover. Check the oil level inside the front brake reservoir.

If the oil level is near the lower limit line, remove the reservoir diaphrag mand fill DOT3 and DOT 4 brake fluid to the top limit line.

If the brake fluid reaches the lower limit line, check

the entire brake system for leaks.

BRAKE PAD/SHOE

BRAKE PAD REPLACEMENT

Check the brake pads for wear. If the rod mark on the pad reaches the brake disc, replace the pads.

BRAKE SYSTEM

Check the front brake hose for cracks or damage. If any leaks are found,replace immediately Check the brake rod for looseness or damage, and replace it if necessary.

BRAKE LEVER FREE PLAY

Check the free play after pulling the lover.

FRONT: 10~20mm REAR: 10~20mm

DUBLE BRAKE HOSE

FRONT CALLIPE

REAR BRAKE HOSE

DRIVEN LEVER

FRONT BRAKE HOSE

REAR CALLIPE

ROD MARK

BRAKE PAD

ROD MARK

BRAKE PAD

0IL CUP CAP

BRAKE FLUID CHECK WINDOW

2-9

INSPECTIONS/ADJUSTMENTS

SIDE STAND

SIDE STAND SWITCH

SIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCH

SIDE STAND SWITCH

2-10

INSPECTIONS/ADJUSTMENTS

TIRE PRESSURE GANGE

TIRE PRESSURE GAUGE

3-1

EXTERNAL PARTS

3

3-2

EXTERNAL PARTS

FRONT COVER

Loosen the 4tapping screws securing the front cover

FRONT COVER

Disconnect the wire grommet Disconnect the front fender Install in the reverse order of removal

FRONT UNDER COVER A

Remove

- Front fender

- Front wheel

-

The 4 tapping screw securing the underside of inner

box

-

The 2 flange bolts and 2 special screw securing front

under cover

-

The screw (right and left) securing the front side of floor

side cover

- Front under cover

- Install in the reverse order of removal

Loosen the tapping screw securing the front cover Disconnect the headlight wiring and winker

00wiring0(right and left)

Install in the reverse order of removal

TAPPING SCREN

TNNER BOX

SPECIAL SCREW

ERONT COVER

FRONT COVER

WIRE GROMMET

ERONT FENER

FRONT FENER

FRONT UNDER COVER

FRONT PORK

TNNER BOX

SPECIAL SCREW

3-3

EXTERNAL PARTS

FRONT HANDLE COVER

Remove the front cover Loosen the 2 tapping screw securing the front handle cover B and remove the handle cover B

Loosen the 5 tapping screw and remove the handle cover Loosen the 1 tapping screw securing front handle

cover and 2 tapping screw securing rear handle cover

Remove the front handle cover Install in the reverse order of removal

REAR HANDLE COVER

Loosen the 2 washer bolt securing front under cover and the 2 tapping screw underside

TAPPING SCREN

HANDIL COVER B

SPEEDO MATER

REAR HANDIL COVER

STEERING HANDIL

TAPPING SCREN

WASHER

3-4

EXTERNAL PARTS

LUGGAGE BOX

Release the seat lock. Release the seat . Loosen the special screw and remove the battery cover.

CENTER COVER

Release the seat lock by turning the main key. Loosen the special screw. Remove the center cover. Install in the reverse order of removal.

FLANGE NET

LUGGAGE BOX

SPECIAL SCREW

BATTERY COVER

OPEN SRAY NUTS

SPECIAL SCREW 2EA

3-5

EXTERNAL PARTS

HANDLE COVER

UNDER

HANDLE COVER

UPPER

FRONT COVER

REAR CARRIER

Loosen the washer bolt(4).

Remove the rear carrier.

Install in the reverse order of removal.

BODY COVER

Loosen the 2 tapping screw securing RH/LH body side cover and 2 special screw

Loosen the body cover clip(R/L).

Disconnect the rear winker wiring and the

body cover opens with right and left and

pull to backside and remove it.

Install in the reverse order of removal

REAR FENDER

Remove

- Luggage box.

- Body cover.

- Loosen the 4 washer bolts.

- Rear fender.

- Tail right wiring.

Install in the reverse order of removal.

REAR FENDER

BODY COVER

4WASHER BOLTS

3-6

EXTERNAL PARTS

FLOOR SIDE COVER

Loosen the screw(R/L) in the floor side cover.

Remove the floor side cover(R/L).

Install in the reverse order of removal.

FLOOR PANER

Remove

- Center cover.

- Body cover.

- Floor panel cap.

- Floor side cover.

- 4 washer bilts.

- pull the floor panel backward to remove it.

- Install in the reverse order of removal.

INTER BOX

Remove

- Front fender.

- Front wheel.

- Front under cover.

- Floor side cover.

- Floor panel.

Loosen.

- 4 tapping screw securing fuel cap neck.

FLOOR SIDE COVER

CENTER COVER

FLOOR PANEL COVER

FUEL CAP NECK

FUEL SUPPLY TUBE

TAPPING SCREN

FLOOR SIDE COVER

3-7

EXTERNAL PARTS

Loosen the special screw securing back holder.

Remove the charge socket cap by turing the

socket cap to loosen the lock securing mainkey.

Remove the inner box.

Install in the reverse order of removal.

UNDER COVER

Remove the floor side cover.

Loosen the special screw (R/L) and remove

the under cover.

Install in the reverse order of removal.

REAR WHEEL MUD GUARD

Loosen the brake hose clamp and washer bolt

securing.

Remove the air cleaner and washer bolt.

securing mud guard.

Remove the rear wheel mud guard.

Install in the reverse order of removal.

SPEEDO METER

Remove

- The speedometer.

- Coupler and wire.

- Rear handle cover.

UNDER COVER

CHARGE SOCKER CAP

BACK HOLDER

SPECIAL SCREW

REAR WHEEL GUARD

SPEEDO METER

EXTERNAL PARTS

3-8

MUFFLER

FIANGE BOLT

EX.CAP NUT

EX.PIPE CAMP

FIANGE NUTS

4-1

LUBRICATION SYSTEM

4

4-1 4-2 4-3 4-3 4-4

4-4 4-7 4-8 4-9

4-2

LUBRICATION SYSTEM

4-3

LUBRICATION SYSTEM

OIL SIGHT GLASS

OIL DRAIN PLUG BOLT

TAPPER ADJUST HOLE CAP

OIL FILTER SCREN

TAPPER ADJUST HOLE CAP

UPPER MIDDLE LOWER

UPPER MIDDIE LOWER

UPPER MIDDLE LOWER

4-4

LUBRICATION SYSTEM

FLANGE BOLTS

OIL FILTER ELEMENT

OIL SEAL

START DRIVEN GEAR

OIL PUMP

FLAT SCEWS

4-5

SERVICE LUBRICATION SYSTEM

4-6

LUBRICATION SYSTEM

INNER ROTOR

OUTER ROTOR

PUMP BODY

OIL PUMP SHAFT

OILPUMP SHAFT

ROLLER

U NUT

U NUT DRIVEN GEAR

DRIVEN GEAR

OIL PUMP

4-7

LUBRICATION SYSTEM

4-8

LUBRICATION SYSTEM

RADIATOR

OIL CHECK BOLT

AC GENERATOR CAP

4-9

LUBRICATION SYSTEM

PILLION STEP

REAR BRAKE DISK

MUFFLER

BATTERY

FR. BRAKE LEVER

REAR VIEW MIRROR

TIRE

BAG HOLDER

MEMO

5-1

EMS(Engine Management System)

5. EMS(Engine Management System)

1. CAUTION WHEN REPAIRING THE EMS PARTS

5-2

2. THE COMPONENT PARTS OF THE EMS 5-3

3.TERMINAL ARRANGEMENT OF THE ECU 5-4

4. WIRING DIAGRAM OF THE ECU 5-4

5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) 5-5

- Self diagnostic function 5-5

- Fail safe function

5-6

- How to check

the fault code

5-7

- How to show the fault code

5-8

- How to read the fault code

5-8

- Fault code table 5-9

- How to remove the fault code 5-10

- EMS trouble shooting 5-10

6. INJECTOR 5-11

7. MAPAT 5-14

8. TPS 5-17

9. ETS 5-20

10. ISA

5-23

11. O

2

(Oxygen) SENSOR 5-26

12. CHECKING OF MIL CIRCUIT 5-29

13. ECU (Electronic control unit) 5-30

14. IGNITION COIL/SPARK PLUG 5-31

15. CPS 5-32

16. FUEL PUMP 5-33

17. THROTTLE BODY 5-36

18. HOW TO USE THE SCAN WHEN THE ECU IS INITIALIZED 5-41

19. HOW TO USE THE SCAN WHEN THE ISA PWM IS ADJUSTING 5-43

20. HOW TO USE THE SCAN WHEN THE IGNITION TIMING IS CHECK 5-44

21. HOW TO USE THE SCAN WHEN ENGINE REVOLUTION IS CHECKING

5-45

5-2

EMS(Engine Management System)

1.CAUTION WHEN REPAIRING THE EMS PARTS.

If the fuse is short-circuited, findout the cause and repair. Replace with the fuse having the specified capacity. Do not use the electlic wires or others instead of the fuse. Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop.

Do not touch the ECU terminal, because it may be damaged by the static.

The ignition key off when assembly and disassembly of the ECU coupler. otherwise, it might be damage to ECU.

Do not connect adversely the polarity of battery. otherwise, It may be broken the EMS parts

While engine operating, do not disassembly the battery terminal.

otherwise, it might cause damaged the EMS parts.

Use the specitied voltmeter and resistance meter.

5-3

EMS(Engine Management System)

2.THE COMPONENT PARTS OF THE EMS

EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM.

1) INTAKE SYSTEM

As a system which controls and measures air to be necessary for combustion in engine, the intake system is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air cleaner and ISA(Idle Speed Actuator), etc. In idling, because throttle value is almost closed, the idle status of engine shall be controlled by means that idle speed control system is installed in order to control small of quantity of air being necessary for combustion.

2) FUEL SYSTEM

As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division pipe and injector. The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter. Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of intake system. Injector sprays fuel into the intake system by injection signals of ECU.

3) IGNITION SYSTEM

The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to control proper spark time in cylinder, high-voltage system, and so forth.

4) CONTROL SYSTEM

Various sensors to move electric signals converted by checking the current engine status Input interface which works various processes like regulating voltage levels, removal of noise, A/D conversion, amplifying of inputted signals from above sensors. Micro-computer which decides output value through various calculating, arithmetic and logic processing. Output interface to amplify the above output signals. Actuator being mechanically worked by receiving the amplified output signals.

(Intake pressure sensor+Intake temperature)

5-4

EMS(Engine Management System)

3. TERMINAL ARRANGEMENT OF THE ECU

Remarks

ECU PIN NO. 6,7,8,11,13,14,15,16,21,29,32,36,38 were not connected.

4. WIRING DIAGRAM OF THE ECU

5-5

EMS(Engine Management System)

5.

SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp)

SELF-DIAGNOSTIC FUNCTION

The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL (malfunction indicator lamp). It gives the rider that malfunction has occurred in the system. However, the ECU takes fail-safe function, it enables to drive only temporary when that happen. Normally, the MIL illuminates for 3 seconds, when the main key is turned on.

Remarks 1

If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMS’s fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.

Remarks 2

It might not be able to starting and driving when following problems happen.

- Crankposition sensor

- Injector

- Fuel pump

when the ignition key ON.

The MIL on and blink(when this function detects a malfunction in the system)

MIL

OFF

ON

Starting and driving are temporary

Unable

MIL

ON

Blink

MIL on continuously, when the engine operating

MIL blinks, when the main key is turn on (engine is stop)

5-6

EMS(Engine Management System)

FAIL-SAFE FUNCTION

If the ECU checks something wrong , the vehicle can be driven by its fail safe function. However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation can be impossible.

If there is something wrong in the EMS, it has fail safe function in order for engine to

work and to cover a minimum driving of vehicle.

: MIL on/off

INTAKE

MIL

INTAKE

: MIL on

on

INTAKE

The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order.

intake

The value of intake temperature is fixed as a temperature just before when the intake pressure sensor is out of order.

!

CAUTION

If the MIL on and blink, starting and driving are temporary by fail safe function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case. In this case, safe repairing of vehicle shall be required.

5-7

EMS(Engine Management System)

HOW TO CHECK THE FAULT CODE

There are two methods of checking the fault codes.

1) Use the MIL in the speedometer.

2) The diagnostic tool.

First) Use the MIL in the speedometer(refer to how to read the fault codes and fault codes table and diagnostic

methods for each part)

Second) The diagnostic tool (refer to scan user’s manual.)

Turn off the ignition key Disassemble the rh.side cover The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.

(The coupler to check the malfunction of vehicle is placed in the rh.side cover)

Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool.

The wireharness to check the ECU

This wireharness is connected with the ECU and main wireharness

It has two couplers to check the terminals. First coupler) ECU no.1~20 Second coupler) ECU no.21~40

Arrangement of ECU PIN

First coupler) ECU no.1,2,3,4,5,9,10,12,17,18,19,20 were connected Second coupler) ECU no.36,38 were not connected

Wire color to check the malfunction diagnosis

-P/W : PINK/WHITE

-P/Y : PINK/YELLOW

-B : BLACK

-G : GREEN

Coupler to check the malfunction diagnosis

The diagnostic Tool.

The wireharness to check the ECU

5-8

EMS(Engine Management System)

HOW TO SHOW THE FAULT CODE

There are two methods to show the Fault codes.

First, the methods to show in engine operation In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the light on/off function of MIL in order for driver to acknowledge defect. This time, so for checking the fault code, stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault code can be verified.(refer to the fault code table)

Second,the ways of indication only turn on the ignition key. When only ignition key is on and if the defect of each part brings out, the MIL keeps showing the Fault code of defect part repeatedly in order to give defect information to driver.

If the MILon when engine is working, engine is able to be operated by fail safe. However, in the event that

Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started

HOW TO READ THE FAULT CODE

The fault codes are showed as 2 digits on the MIL of EMS. Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly showed. E.g. ) The Fault code of ISA

If many problems will happened in the EMS parts at the same time only one fault code is displayed by the priority, however, the ECU is remembers all the fault codes. After revise the code, remove the memorized fault code by the method of warm up.(5-10) (Refer to remove the fault codes)

When the vehicle is checked using the diagnosis tool.

- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.

1 flashing cycle : 0.5 sec

1.5 sec 3 sec

ON

OFF

!

CAUTION

5-9

EMS(Engine Management System)

FAULT CODES TABLE

No failure

Injection valve failure(IV)

Idle speed actuator failure (ISA)

Electrical fuel pump failure (EFP)

Intake Manifold absolute pressure signal failure (IMP)

Throttle position signal failure (TPS)

O2 sensor heater output failure (LSH)

Lambda signal failure (VLS)

Engine temperature signal failure (TENG)

Breathing air temperature signal failure

(TBA)

Malfunction indicate lamp failure (MIL)

5-10

EMS(Engine Management System)

HOW TO REMOVE THE FAULT CODE

Remove the fault codes in two ways;

First) Full warm up

1. Starting the engine.

- The MIL blinks continuously because the ECU memorized the fault code yet.

2. Full warm up the engine (keep idling five minutes)

3. Turn off the ignition key after full warm up the engine

4. Turn on the ignition key again, and check whether the fault code is disappeared or not.

After full warm up, it is possible to check the fault code is removed with the ignition key on/off.

If many problems happened in the EMS parts at the same time, only one defect code will is displayed by the priority order. Even thought repair a fault and remove the memorized fault code, another fault code blinks. at this time, revise the fault and remove the memorized fault code by the warm up.

Second) Malfunction diagnosis tool

(refer to the scan user’s manual)

EMS TROUBLE SHOOTING

Inspection before diagnosis

Inspection the following before malfunction diagnosis.

Quantity of engine oil and leakage Quantity of fuel and leakage Blocked of air cleaner Condition of battery Free play of throttle cable Cutting of fuse Leakage of emission gas Connection of each coupler

5-11

EMS(Engine Management System)

Remove

Connector Connector bolt Injector and injector cap. Replace the injector

6.INJECTOR

!

NOTICE

Before disassemble, the key is off.

!

CAUTION

Make sure that dust does not enter the throttle body insulator.

5-12

EMS(Engine Management System)

CHECKING METHODS BY FAULT CODES

Checking of the Injector circuit

The fault code is displayed by MIL

Checking Circuit

Coupler terminal is based on wire harness.

Checking Procedure

1) Turn off the ignition key.

2) Check to see if the injector coupler has come loose or the wire is peeling off. If there is no problem, measured the resistance of injector.

3)Disassemble the injector coupler and measure the resistance between injector terminals.

The resistance of injector : 14.5±0.7[ ], 20

Remarks : measuring unit for resistance : resistance ‘ R ‘ [ ]

4)If there is no problem, check the continuity between each terminal and ground.

The resistance between each terminal and ground : ∞[ ] If resistance value is not normal, replace injector with the new one.

5)If the resistance is normal, turns on the ignition key

- If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.

6) Measure between the voltage of coupler. Measuring terminal : BLACK/RED electric wire ~ ground Measuring voltage : battery voltage – 1.0[V]over

Remarks : Measuring unit of voltage : voltage [V]

ECU

40 : INJECTOR control

39 : FUEL PUMP control

INJECTOR FUEL PUMP RELAY

5-13

EMS(Engine Management System)

7) If the measured voltage is normal, Check the ‘Blue/Yellow’ electric wire to see if they have been broken or have short-circuited

or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)

If there is no problem in the electric wires, ECU is broken Replace the ECU with new one, it rechecks

8) If the measured voltage is not normal, Check the Black/Red electric wire to see if they have been broken or have short-circuited. Check the fuel pump relay.

9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

7. MAPAT(Manifold Air pressure sensor, Temperature sensor)

Remove

MAPAT connector (Push by hand and pull to the front-side) Loosen the flange bolt 2EA.

Be sure to check the coupler is toward to insulator.

!

CAUTION

Located on the left- side of the throttle body

Before disassembly, the key is off.

!

CAUTION

5-14

EMS(Engine Management System)

ISA

TPS

MAPAT

5-15

EMS(Engine Management System)

Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit

Fault code number is displayed by MIL

The Fault code of intake pressure sensor The Fault code of intake temperature sensor

Checking circuit

Coupler terminal is based on the side of wire-harness

Checking Procedure

1) Turn off the ignition key .

2) Check to see if the MAPAT coupler has come loose or the wire is peeling off. If there is normal, measured the input voltage of MAPAT’s coupler.

3) Disassemble the coupler of MAPAT and turn on the ignition key

4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)’s coupler.

Input voltage : 4.5 ~ 5.5[V] Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal

Remarks : Measuring unit of voltage : voltage [V]

If voltage value is not normal,

Check to see if the ECU coupler is loose or if there is a bad contact. Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ to see if they have been broken short-circuited

Remark : refer to (5-16) if the intake pressure sensor is broken

refer to (5-16) if the intake temperature sensor is broken

5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

3 : Intake pressure sensor ground 26 : 5V voltage 27 : IMP 28 : TBA

MAPAT

3 : Inhalation pressure sensor GROUND 26 : 5V voltage

ECU

27 : IMP 28 : TBA

5-16

EMS(Engine Management System)

Checking of the intake pressure sensor

1) If voltage value is normal, turn off the ignition key. Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler

2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-32 )

3) Turn on the ignition key. Start engine and operate idle.

4) Measure the voltage of intake pressure sensor for ECU check.

Measuring the voltage of intake pressure sensor. Measuring terminal : ECU No. 27(P/L:PINK/BLUE) ~ ECU No.3(P/G : PINK/GREEN) Measuring voltage : 0.1[V] ~ 4.8[V]

Remarks : Measuring unit of voltage : Voltage [V]

The voltage of air pressure; 20[kPa]: 0.719 ~ 0.859[V] 107[kPa]: 4.154 ~ 4.294[V]

5) If the measured voltage is not normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’ electric wire to see if they have been broken

or have short- circuited.

Replace the MAPAT sensor with the new one and it rechecks.

If measuring voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have short- circuited if there is a bad contact.

badness of terminal No. 3, No. 26, No.27 of ECU coupler.

If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks.

6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU.

Checking of the intake temperature sensor

1) If voltage value is normal, turn off ignition key.

2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor.

Resistance of intake pressure sensor : 2000±100[Ω], 25±1 Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)

Remarks : Measuring value for resistance : Resistance[ ]

The Voltage of air pressure; 24 ~ 26[ ] : 1800~2200[ ] 99 ~ 101[ ] : 161~206[ ]

3) If measuring resistance is not normal,

Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 3, No. 26, No. 28 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks.

5-17

EMS(Engine Management System)

8.TPS(THROTTLE POSITION SENSOR)

Remove

Lh.side cover Air cleaner TPS connector TPS screw Replace the TPS

It is Located on the right side of throttle body

Before disassembly, the key is off.

!

CAUTION

Checking of intake temperature sensor

4) Turn on the ignition key. Start the engine and idling.

5) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor

- Measuring terminal: ECU No.28(TBA) ~ ECU No.3(IMP GROUND)

- Measuring voltage: 0.1[V] ~ 4.9[V]

Remarks : Measuring unit of voltage : Voltage [V]

6) If the measured voltage is not normal, Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’ electric wire to see if they have been broken

or have short- circuited.

Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have

short- circuited if there is a bad contact of terminal No. 3, No. 26, No.28 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace ECU with the new one, it rechecks.

7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM

Fault code number displayed by MIL

Checking circuit

The coupler terminal is based on the side of wire-harness

Checking Procedure

1) Turn off ignition key .

2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of TPS.

3) Disassemble the TPS coupler

4) Turn on the IGNITION KEY.

Input voltage : 4.5 ~ 5.5[V]

Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED) Measure the terminal voltage of TPS’s coupler. Measuring voltage : 4.5[V] ~ 5.5[V]

Remarks : Measuring unit of voltage : voltage [V]

If voltage value is not normal,

Check to see if the ECU coupler is loose if there is bad contact.

Check the ‘GR/B’’ electric wire, ‘W/R’ electric wire, ‘GR /L’ electric wire to see if they have been

broken or have short- circuited.

5) If the value of voltage is normal, turn off the ignition key.

5-18

EMS(Engine Management System)

TPS

4 : SENSOR GROUND

ECU

18 : 5V SUPPLY VOLTAGE

19 : TPS

5-19

EMS(Engine Management System)

Checking Procedure

6) Check continuty between the Sensor Ground Terminal of TPS and Earth.

The continuty TPS : 0[ ],20±1 Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH

Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ ]

7) If not problem, measure the resistance of TPS. By turning round throttle leve, measure the resistance. The resistance of TPS If the throttle is totally closed : 1.38~1.6[k ],20±1 If the throttle is totally opened : About 2.4[k ],20±1 Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No.4 (W/R : WHITE/RED)

Remarks : Measuring value of resistance : Resistance[k ]

8) If resistance and the continuty are not abnormal. Adjust correctly the position of TPS Replace the TPS with the new one and re-check.

9) If resistance and continuty are normal, connect the TPS coupler.

10) Turn on the ignition key.

11) Measure the TPS voltage of wire-harness check the ECU. Rotate the throttle lever, measure the voltage

Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No.4 (W/R : WHITE/RED)

Output voltage of TPS

-If the throttle is totally closed : 0.1~0.6[V]

-If the throttle is totally opened : 4.0~5.5 [V]

Remarks : Measuring unit for voltage : Voltage [V]

12) If the measured voltage is abnormal, Replace the TPS with the new one, and re-check.

If the measured voltage is normal,

Check the ‘GR/B’ electric wire, ‘GR/L’ electric wire, ‘W/R’ electric wire to see if they have been broken or

have short- circuited if there is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler. If there is no problem in wires, ECU has broken down. Replace ECU with the new one, and recheck.

13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

9.ETS(ENGINE TEMPERATURE SENSOR)

Remove

Rh.shroud comp Connector by hand ETS Replace the ETS

Install in reverse order of removal

Situated on the Right-hand side of cylinder head

Before disassembly, the key is off.

!

CAUTION

5-20

EMS(Engine Management System)

ETS torque:3±0.3[kgf m]

!

CAUTION

PUSH

PULL

5-21

EMS(Engine Management System)

1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)

Fault code number is displayed by MIL

CHECKING CIRCUIT

Coupler terminal is based on the side of wire-harness

Checking Procedure

1) Turn off the ignition key .

2) Check the ETS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of ETS.

3) Disassemble the coupler of ETS

4) Turn on ignition key.

Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE) ~ ECU No.4 (W/R : WHITE/RED)

Measure the terminal voltage of ETS’s coupler. Measuring voltage : 4.5[V] ~ 5.5[V]

Remarks : Measuring unit for voltage : voltage [V]

If the voltage value is not normal,

Check to see if the ECU coupler is loose if there is bad contact.

Check the ‘G/L’’ electric wire, ‘W/R’ electric wire, ‘W/R’ electric wire to see if they have been

broken or have short- circuited.

5) If the voltage value is normal, turn off the ignition key.

6) Disassemble the coupler of ETS, and measure the resistance of ETS.

Resistance of ETS :1.6[k ]~10.6[k ],20 ~80 Measuring terminal : Each terminal of ETS

Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [k ]

ETS

ECU

4 : SENSOR GROUND 20 : ETS

5-22

EMS(Engine Management System)

6-1) If the measured value is not normal,

Replace the ETS with the new one, recheck.

If the measured value is normal,

Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if

the ECU coupler is a bad contact ( No.4, No. 20.) If the electric wire is no problem, ECU is broken. Replace ECU with the new one, recheck.

6-2) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

Checking Procedure

1) Disassembly Disassemble the ETS(Engine Temperature Sensor) : (Refer to 4-20)

2) Check the ETS(Engine Temperature Sensor) Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil. Read the temperature of thermometer depending upon oil temperature’s change and tester’s value.

Characters of ETS

Measuring unit of resistance : Resistance ‘ R ‘[k ]

If the value of resistance is high or out of the standard value, replace the ETS with the new one.

1)Be careful do not fell down the ETS, because its weakness.

2)Be careful the ETS and the thermometer do not to touched to oil bowl.

3)Be careful oil temperature will not raised more than measurement temperature.

3) Install Install in the reverse order of removal with standard torqve.

ETS torque : 3.0[kgf

m]

Temperature

20

80

110

Resistance value

10.6[k

]~14.4[k ]

1.35[k ]~1.65[k ]

0.57[k

]~0.69[k ]

!

CAUTION

5-23

EMS(Engine Management System)

10.ISA(IDLE SPEED ACTUATOR)

Remove

SEAT Maintenance cover ISA connector

It is located upwards on the throttle body

Before disassembly, the key is off.

!

CAUTION

O-Ring

ISA

1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.

Showing of defects codes by MIL

CHECKING CIRCUIT

Coupler terminal is based on the side of the wire-harness

CHECK PROCEDURE

1) Turn off ignition key .

2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad.

If there is no defect, measure the input voltage of ISA

3) Disassemble the coupler of ISA, measure the resistance

between ISA terminals.

ISA resistance : 31.5~ 38.5[ ],20

remarks : Measuring unit of resistance : Resistance ‘R’[ ]

4) If there is not problem, check about the level of electricity flow between each terminal, and between each ground.

Resistance between each terminal , and between each ground : ∞[ ] If measure resistance value is not normal, replace with the new one Disassembly and Assembly : refer to ( 5-23 )

remarks : Measuring unit for resistance : Resistance ‘R’[ ]

5-24

EMS(Engine Management System)

ISA

ECU

33 : ISA CONTROL 39:FUEL PUMP

FUEL PUMP RELAY

5-25

EMS(Engine Management System)

CHECK PROCEDURE

5) If the measured resistance and continuty is abnormal. Replace ISA with the new one, and recheck.

6) If resistance and continuty is normal, connect the coupler of ISA.

7) Turn on ignition key

8) Measure ISA voltage of wire-harness to check ECU. Measuring terminal : B/R electric wire ~ EARTH Output voltage of ISA : 10~14[V]

Remarks : Voltage measuring unit : Voltage [V]

If the measured voltage is normal,

Check the ‘B/R’ electric wire, ‘L/G’ electric wire, ‘W/R’ electric wire to see if they have been broken or

have short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler.

If there is no problem in wires, ECU has broken down.

Replace ECU with the new one, recheck.

If the measured voltage is abnormal,

Check the ‘B/R’’ electric wire, ‘L/G’ electric wire, ‘W/B’ electric wire to see if they have been

broken or have short- circuited.

9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

Remove

SEAT O2 sensor connector Muffler O2 sensor

Located on the exhaust pipe

Before disassembly, the key is off.

!

CAUTION

Beware of muffler after driving as it is still hot to be burnt

!

Warning

11.O2(Oxygen) SENSOR

5-26

EMS(Engine Management System)

O2 Sensor

5-27

EMS(Engine Management System)

1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT

Fault code number is displayed by MIL

Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.

CHECKING CIRCUIT

Coupler terminal is based on the side of Wire-Harness.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER

1) Turn off the ignition key.

2) Check the O2(oxygen) coupler is loose, or bad. If there is no defect, measure the input voltage of O2(oxygen)

3) Disassemble the coupler of oxygen(O2)sensor and turn on ignition key

4) Measure input voltage of oxygen(O2)sensor coupler

Input voltage : Battery voltage[V] Measuring terminal (side of Wire-harness) : oxygen(O2)3 terminal of sensor coupler

(B/BR : BLACK/BROWN) ~ EARTH

Remarks : Measuring unit of Voltage : Voltage[V]

OXYGEN SENSOR

2 : LAMBDA SENSOR GROUND

ECU

12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER

5-28

EMS(Engine Management System)

CHECKING FOR A FAULT CODE BY OXYGEN(O

2)SENSOR HEATER

If the voltage value is abnormal,

Check to see if the ECU coupler is loose or if there is bad contact.

Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been broken or have short- circuited.

5) If the voltage value is normal, turn off the ignition key. Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22 Measuring terminal (side of wire-harness) : oxygen(O2)3 terminal of sensor coupler

(B/BR : BLACK/BROWN) ~ ECU No.34(G/W :GREEN/WHITE)

Remarks : Measuring unit of Resistance : Resistance ‘R’[ ]

6) If the measured resistance is abnormal, Replace the oxygen(O2)sensor with new one and recheck it.

If the measured resistance is normal,

Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been

broken or have short- circuited. If the electric wire is no problem, the ECU is broken. Replace the ECU with new one, and recheck it.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL

1) Turn off the ignition key

2) Check the O2(oxygen) coupler is loose, or bad. If there is no defect, measure the input voltage of O2(oxygen)

3) The wire harness to check the ECU is connected to the ECU with a ECU coupler

refer to the ECU assembly/disassembly (4-34)

4) Turn on the ignition key

5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU. Measuring terminal: ECU No.12(V :VIOLET)~ ECU No.2(V/B:VIOLET/BLACK) Output voltage of oxygen(O2) sensor : 0.1~0.8[V]

Remark : measuring unit of voltage : voltage[V]

Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf

If the measured voltage is normal,

Check the ‘B/R’ electric wire, ‘V’ electric wire, ‘V/B’ electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 2, No. 12 of ECU coupler. If there is no problem in wires, ECU has is broken.

Replace the ECU with new one, and recheck it.

If the measured voltage is abnormal,

Check the ‘V’ electric wire, ‘V/B’ electric wire, ‘W/B’ electric wire to see if they have been

broken or have short- circuited.

6) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

5-29

EMS(Engine Management System)

12.CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT

Fault code number is displayed by MIL

CHECKING CIRCUIT

CHECK PROCEDURE

1) Turn off ignition key.

2) Check the ESS coupler is loose, or bad. If there is no problem.

3) Turn on the ignition key.

4) Check the MIL on for 3 seconds when turn on the ignition key at the same time. If there is no lighting, check the lamp. But If the lamp is working for 3 second,

5) Measure the MIL voltage of wire harness to check ECU. Measuring terminal : B electric wire ~ EARTH => Output voltage: battery voltage Measuring terminal : ECU No.24(L/B :BLUE /BLACK) ~ EARTH => output voltage:

battery voltage

Remarks : measuring unit of voltage : voltage[V]

If the measured voltage is normal,

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler. If there is no problem in wires, ECU has is broken. Replace the ECU with new one, and rechecks it.

If the measured voltage is abnormal,

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric wire to see if they have been

broken or have short- circuited.

6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

ECU

24 : MALFUNCTION INDICATOR LAMP OUTPUT

MALFUNCTION INDICATOR LAMP(MIL)

5-30

EMS(Engine Management System)

Remove

Body cover Connector (A display portion is pulled behind) Flange bolt 4 EA Replace the ECU

Install in the reverse order of removal. Replace the ECU

Located inside the LH. side cover

!

CAUTION

Be sure to assemble the ECU ground wire. (The color is green)

!

CAUTION

13.ECU(ELECTRONIC CONTROL UNIT)

Make sure that the key is off before disassembly

ECU ground wire

5-31

EMS(Engine Management System)

Remove

SEAT Body cover Ignition coil

-Connector

-Spark plug cap

-Ignition coil bolt 2EA

-Ignition coil

Locate on the RH.body cover

Be sure to check the engine is cooling. because a little gasoline remains, it is still hot.

!

CAUTION

Be sure to assemble the IG coil Ground wire. Be sure to check the high tension cord is assembly like a picture.

Install in the reverse order of removal.

!

CAUTION

14.IGNITION COIL

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

IG coil

ground wire

EMS(Engine Management System)

5-32

Remove

Connector

- CPS connector(BLUE, LIGHT GREEN)

- ACG connector(YELLOW) RH.shroud Cooling fan Flywheel Stator CPS screw Replace the CPS

ENG RH.crankcase cover

Before disassembly, the key is off.

!

CAUTION

Install in the reverse order of removal.

15.CRANK POSITION SENSOR :CPS

CPS wire

5-33

EMS(Engine Management System)

Remove

Fuel pump nut 4EA Replace the fuel pump injector cap

Do not push the fuel pump base under the fuel

tank when the fuel tank is stored.

Always replace the packing when the fuel pump

is removed.

Before disconnecting the fuel hose, release the fuel pressure by loosing the fuel hose banjo bolt at the fuel tank

Always replace the sealing washers when the fuel hose banjo bolt is removed or loosened.

Located below the floor panel

Before disassembling, the key is off.

!

CAUTION

16.FUEL PUMP

NOTICE

EMS(Engine Management System)

5-34

The terminal arrangement of the fuel pump

(The following color chart is the internal color of the fuel pump)

16.FUEL PUMP

5-35

EMS(Engine Management System)

Remove the fuel level gauge (19-10) Measure the resistance between terminals.

The float position is based on the tank bottom plate after assemble.

Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)

wire of fuel unit terminal

Remark : measuring unit of resistance : resistance[ ]

If the measured resistance value is out of standard at float position, replace the fuel unit.

CHECKING OF THE FUEL LEVEL GAUGE.

The FLOAT position

F : 128.5[mm]

1/2 : 83.5[mm]

E : 28.5[mm]

Terminals resistance [

]

40

5[ ]

220

5[ ]

400

3[ ]



5-36

EMS(Engine Management System)

17.THROTTLE BODY

THROTTLE BODY

ISA

TPS

MAPAT

5-37

EMS(Engine Management System)

Disconnect:

- Luggage box

- TPS,ISA,MAPAT coupler

- Throttle cable

Do not disconnect both the throttle adjust screw

and adjusting nut

DISCONNECT THE THROTTLE BODY

CHECKING THE THROTTLE BODY

DISASSEMBLE THE THROTTLE BODY

!

CAUTION

- Disconnect the insulator and the connecting tube band 2ea at the air cleaner side.

- Disconnect the TPS (Throttle position sensor)

- Disconnect the ISA (Idle speed actuator)

- Disconnect theMAPAT

Do not disconnect the throttle valve

!

CAUTION

Check:

- Throttle shaft

- Throttle valve

MAPAT

ISA

TPS

O-RING

5-38

EMS(Engine Management System)

Disconnect:

- Injector cap bolt

- Injector and injector cap at the same time

from the insulator

- Injector and injector cap.

DISASSEMBLE THE INSULATOR

CHECKING THE INSULATOR

Check:

- O-ring

- Insulator

- Injector

ASSEMBLY OF THE INSULATOR

Assemble is the reverse order

of removal.

. Assemble the o-ring to insulator.

!

CAUTION

INSULATOR

INJECTOR

INJECTOR CAP

Replace the o-ring with new one.

5-39

EMS(Engine Management System)

ASSEMBLY OF THE THROTTLE BODY

Assembly is the reverse order of removal. Assemble the o-ring to the throttle body.

INSTALLATION OF INSULATOR AND THROTTLE BODY

Installation of insulator and throttle body in the reverse order of removal Check the o-ring when the insulator assembly. Assemble the insulator gasket.

ADJUSTMENT OF THROTTLE CABLE

INSPECTION OF SENSOR AND ACTUATOR

Assemble the throttle cable Adjust the free play of the throttle grip ( -4)

Connect each sensor and the actuator’s coupler. Check the ISA (Idle speed actuator) ( -23) Check the TPS (Throttle position sensor ( -17)

!

CAUTION

!

CAUTION

!

CAUTION

Replace the o-ring with new one.

Replace the gasket with new one. The assembled insulator and throttle body assemble to cylinder head. Torque : 1.2 kgf m

Be sure to the value of TPS is whether the standard value after it became assembly. Check the MAPAT sensor ( -14)

5-40

EMS(Engine Management System)

ADJUSTMENT OF THROTTLE ADJUST SCREW

A vehicle is assembled in the state which engine

operation is possible.

Loosen the maintenance cover and the adjust-screw

is makes possible to adjust.

The coupler to check the malfunction of vehicle is

connected to the coupler of diagnostic tool.

Turn on the ignition key. Press the power-button of diagnostic tool.

SUPPLEMENT

The ECU is always initialized, before the engine is starting.

The vehicle is warms up enough to adjust the idling speed.

!

CAUTION

If the ETS temperature is 90 degrees, adjust the‘ throttle adjust screw’.

!

CAUTION

By adjusting the throttle adjust screw. Adjust the value of ISA PWM to standard value, among the service data of diagnostic tool. ISA PWM : 12 2%, 1600 100RPM After the ISA PWM became adjusted, fix the throttle adjust screw with adjusting nut.

5-41

The coupler to check the malfunction of vehicle

is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnostic tool. Press the enter button in the initial screen. Press the enter in the vehicle diagnosis screen.

Press the enter button on the resetting ECU values.

Press the rest button on the following screen.

If the enter-key is press than the ECU will reset.

18.HOW TO USE THE SCAN WHEN ECU IS INITIALIZED

EMS(Engine Management System)

Press the enter button when it is ready

When the ECU was initialized. turn off the lgnition

key and then turn on the ignition key.

EMS(Engine Management System)

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The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen. Press the button at the vehicle diagnostic screen.

Press the enter button on the current data.

By looking the displayed figure on the ISA PWM,

adjust the throttle adjust screw.

19.HOW TO USE THE SCAN WHEN THE ISA PWM IS ADJUSTING

EMS(Engine Management System)

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EMS(Engine Management System)

The coupler to check the malfunction of vehicle is

connected to the coupler of diagnostic tool.

Turn the lgnition key. Start the engine. Press the power button of the diagnosis tool. Press the enter button on the initial screen. Press the enter button on the vehicle diagnosis screen.

Press the enter button on the current data.

To check the ignition angle

20.HOW TO USE THE SCAN WHEN THE IGNITION TIMING IS CHECKING

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