Hyundai 4WD Specifications

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4 Wheel Drive (4WD) System > General Information > Specifications

Specification

Items Specification

Oil

Type Hypoid gear oil, SAE 75w/90, API GL-5

Capacity 0.6L (0.16 U.S.gal., 0.63 U.S.qt, 0.53 Imp.qt.)

4 Wheel Drive (4WD) System > Transfer Assembly > Front Wheel Transfer Assembly > Components and Components Location

Component

1. Rear flange assembly

2. Pinion shaft

3. Pinion case

4. Spacer

5. Transfer housing

6. Hypoid gear shaft assembly

7. Transfer cover

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4 Wheel Drive (4WD) System > Transfer Assembly > Front Wheel Transfer Assembly > Repair

procedures

Inspection

Transfer Oil Inspection

Transfer oil should be inspected and refilled every 30 months or 37,500 miles.

Tightening torque

Oil drain pulg(A) :

39.2~58.8N.m (4.0~6.0kgf.m, 28.9~43.4lb-ft) Filler pulg(B) :

39.2~58.8N.m (4.0~6.0kgf.m, 28.9~43.4lb-ft)

Transfer Oil Replacement

1. Transfer oil is not replaced in normal condition.But it shoud be replaced every 75,000 miles in severe driving conditions.

Severe driving conditions

1. Driving in dusty, rough roads

2. Drivng in mountains areas

3. Driving for patrol car, taxi, commercial car or vehicle towing

4. Driving over 170Km/h

Transfer oil should be replaced if the transfer assembly is fall into the water.

Remova

1. Disconnect the (-) terminal from the battery.

2. Lift up the vehicle.

3. Remove the front muffler

4. Remove the propeller shaft bolts.(A-4ea)

Tightening torque :

49.0~68.6N.m (5.0~7.0kgf.m, 36.2~50.6lb-ft)

Install the propeller shaft to be near runout marking (Transfer assembly 1ea, Propeller shaft 1ea) each other.

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5. Remove the right driveshaft (passanger side) from the transfer case. (Refer to "Drive shaft" in DS group)

6. Remove the roll lod bracket(C) after removing bolt(A,B).

Tightening torque :

(A) 107.9~127.5N.m (11~13kgf.m, 79.6~94.1lb-ft) (B) 49.0~63.7N.m (5.0~6.5kgf.m, 36.2~47.0lb-ft)

7. Remove the transfer case up and down mounting bolt (A-4ea, B-1ea).

Tightening torque :

(A, B) 60.8~65.7N.m (6.2~6.7kgf.m, 44.8~48.5lb-ft)

8. Remove the transfer case with the lever after supporting the transfer case with a jack.

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Installation

1. Installation is the reverse of removal.

• Be careful not to damage the O-ring (A). If the O-ring take damage, replace new one.

• Smear involute splines (B) all covering with molybdenum type high pressure grease.

TECHLUBE MEGAMAX - ALPHA OR EQUIVALENT

4 Wheel Drive (4WD) System > 4WD Control System > 4WD ECU > Components and Components Location

Components Location

Page 6

4 Wheel Drive (4WD) System > 4WD Control System > 4WD ECU > Schematic Diagrams

1. 4WD ECU Harness connecto

2. 4WD ECU Terminal Function

Pin No. Description

1NC

2NC

3NC

4CAN HIGH

5IG

6 BATTERY

7NC

84WD SOL +

9 LOCK MODE SW

10 NC

11 NC

12 CAN LOW

13 NC

14 NC

15 GROUND

16 4WD SOL -

4 Wheel Drive (4WD) System > 4WD Control System > 4WD ECU > Description and Operation

Description

Four Wheel Drive (4WD) transfer mode selection

1. AUTO MODE:

- When driving in 4WD AUTO mode, the vehicle operates similar to conventional 2WD vehicles under normal operating conditions. However, if the system determines that there is a need for the 4WD mode, the engine’s driving power is distributedto all four wheels automatically without driver intervention.

- When driving on normal roads and pavement, the vehicle moves similar to conventional 2WD vehicles.

2. LOCK MODE:

- This mode is used for climbing or descending sharp grades, off-road driving, driving on sandy and muddy roads, etc., to maximize traction.

- This mode automatically begins to deactivate at speeds above 30 km/h (19 mph) and is shifted to 4WD AUTO mode at speed above 40 km/h (25 mph). If the vehicle speed decelerates to below 30 km/h (19 mph), however,

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Operation

• Normal driving situation: 2WD base driving

• 4WD driving in driving situations (rapid activation, cornering etc.)

1. Input the information from each sensor in vehicle A. Input torque (Throttle position sensor)

B. Cornering situation (Steering angle sensor)

C. Vehicle speed and different wheel speed front &rear (Wheel speed sensor)

D. Braking situation (Brake signal and ABS signal)

2. Distributed the required driving force after 4WD ECU operates.

3. EMC (Electric Magnetic Clutch) operates the primary clutch.

4. Control the cam's opening gap by operation of primary clutch.

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5. Control the slip of inner & outer plate.

Control variably the driving force distribution to optimize front & rear driving force.

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4 Wheel Drive (4WD) System > 4WD Control System > 4WD ECU > Repair procedures

lacement

1. Remove the lower panel. (Refer to "Crash Pad" in BD group)

2. Remove the IPM.(Refer to "Fuses and Relays" in BE group)

3. Remove the parking brake pedal.(Refer to "Parking Brake System" in BR group)

4. Remove the 4WD ECU(C) after removing the nut (A-2ea) and the connector (B).

Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

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(ITCC) > Components and Components Location

Component

1. Magnetic Clutch

2. Pilot clutch

3. Cam

4. Main clutch

5. Housing

6. Flange

4 Wheel Drive (4WD) System > Coupling Assembly > Intelligent Torque controlled Coupling (ITCC) > Repair procedures

Remova

1. Remove the 4WD coupling assembly bolts (A-3ea) mounted to the rear propellar shaft (B).

Tightening torque :

49.0~68.6N.m (5.0~7.0kgf.m, 36.2~50.6lb-ft)

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2. Using a flat tool, separate the propellar shaft from 4WD coupling assembly.

3. Remove the electric magnetic clutch connector(A).

4. Remove the 4WD coupling assembly mounting bolts (A-4ea).

Tightening torque :

58.8~63.7N.m (6.0~6.5kgf.m, 43.4~47.0lb-ft)

5. Using a flat tool, separate the 4WD coupling assembly from the rear differential carrier assembly.

Installation

1. Installation is the reverse of removal.

• Grease the drive gear of the differential carrier assembly.

High pressure grease KLUBER MICROLUBE GNY 202 or equivalent GREAS

• Spread sealant on the matching face of coupling & differential carrier.

Sealant material FIPG(Formed in Place Gaskets)-B (MS721-40) or equivalent to LT5702

-TRANSMISSION (MS511-55, TMG-2)

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• Remove oil on the matching face before spread sealant.

• Refer to instruction drawing for spreading line.

• Staring point anding point should be overlapped (min.10mm(0.3937in.))

• Be sure to assemble part "Coupling & Differential carrier" within 3 minutes after spread sealant.

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Automatic Transaxle System > General Information > Specifications

ecification

Item Specification

Transmission type A6MF1

Engine model Gasoline 2.0 Gasoline 2.4

Torque converter type 3-element, 1-stage, 2-phase type

Torque converter size Ø236 mm (9.2913 in.)

Oil pump system Parachoid

Clutch: 2EA

Friction elements

Planetary gear 3EA

1st 4.162 4.212

2nd 2.575 2.637

3rd 1.772 1.800

Gear ratio

Final gear ratio 3.648 3.195

Fluid pressure balance piston 3EA

Accumulator 4EA

Solenoid valve 8EA (VFS:6EA, ON/OFF:2EA)

Shift lever position 4 Range (P,R,N,D)

Oil filter 1EA

4th 1.369 1.386

5th 1.000 1.000

6th 0.778 0.772

Reverse 3.500 3.385

Brake: 3EA

OWC : 1EA

VFS: Variable Force Solenoid

Tightening Torque

Item N.m Kgf.m lb-ft

TCM installation mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

Shift cable bracket mounting bolt 14.7 ~ 21.6 1.5 ~ 2.2 10.9 ~ 15.9

Input shaft speed sensor mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Output shaft speed sensor mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Shift lever assembly bolt 8.8 ~ 13.7 0.9 ~ 1.4 6.5 ~ 10.1

Inhibitor switch mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Valve body cover mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Eyebolt 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.6

Oil drain plug 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.6

Oil level plug 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.6

Torque converter mounting bolt 45.1 ~ 52.0 4.6 ~ 5.3 33.3 ~ 38.3

Automatic transaxle upper mounting bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.3 ~ 39.8

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Automatic transaxle support bracket bolt 88.3 ~107.9 9.0~11.0 65.1 ~ 79.8

Lubricant

Item Specified lubricant Quantity

SK ATF SP-Ⅳ, MICHANG ATF SP-Ⅳ, NOCA ATF SP-

Transaxle fluid

Ⅳ, Hyundai Genuine ATF SP-Ⅳ

or other brands meeting the above specification

approved by Hyundai Motors Corp.

7.1L (1.88 U.S gal., 7.50 U.S.qt.,

6.24 Imp.qt.)

Sealant

Item Specified sealant

Rear cover

Torque converter housing

Valve body cover

LOCTITE FMD-546 or THREE-BOND TB1281B

Automatic Transaxle System > General Information > Special Service Tools

Special Service Tool

Tools

(Number and name)

09200-38001 Engine support fixture (Beam)

09200-2S000 Engine support fixture (Supporter)

09453-3L241 Oil seal installer

09231-H1100 Bar

Illustration Use

Removal and installation of the transaxle. Except lower supporter, use beam only with new engine support fixture supporter(SST No.:09200-2S000)

Removal and installation of the transaxle. Use this supporter with the upper beam of the engine support fixture(SST No.:09200-38001)

Installation of transaxle case oil seal. [Using with handle (SST No.:09231-H1100)]

Installation of transaxle case oil seal. [Using with oil seal installer (SST No.:094533L241)]

Automatic Transaxle System > Automatic Transaxle System > Repair procedures

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Oil level Check

A check of ATF level is not normally required during scheduled services. If an oil leak is found, perform the oil level check procedure after repairs are completed.

When checking the oil level, be careful not to enter dust, foreign matters, etc. from fill hole.

1. Remove the eyebolt (A).

Eyebolt tightening torque:

34.3~44.1 N.m (3.5~4.5 kgf.m, 25.3~32.6 l

The gasket of the eyebolt use new one.

2. Add ATF SP-IV 700cc to the ATF injection hole.

-ft)

3. Start the engine. (Don’t step on brake and accelerator simultaneously.

4. Confirm that the temperature of the A/T oil temperature sensor is 50~60°C(122~140°F) with the GDS.

5. Shift the select lever slowly from “P” to “D”, then “D” to “P” and repeat one more at idle.

Keep on each speed position more than 2 sec.

6. Lift the vehicle, then remove the oil level plug (A) from the valve body cover.

At this time, the vehicle must be a horizontal state.

7. If the oil flows out of the overflow plug in thin steady stream, the oil level is correct.

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Oil level check (excess or shortage) method

• Excess: Oil flows out in thick stream.

• Shortage: No oil flows out of the overflow plug.

If there is no damage at the automatic transaxle and the oil cooler, the oil cooler hose, transaxle case, valve body tightening state are normal, ATF must drop out after performing above 1 to 7 procedures. After performing above 1 to 7 procedures, if the oil doesn’t drop out, inspect the automatic transaxle assembly.

The gasket of the oil level plug use new one.

Oil level plug tightening torque:

34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~32.6 l

8. Put down the vehicle with the lift and then tighten the eyebolt.

-ft)

Replacement

ATF of 6 speed automatic transaxle doesn’t be replaced. But, if the vehicle is severe use or business use, replace ATF every 60,000 miles for severe usage. Severe usage is defined as

• Driving in rough road (Bumpy, Gravel, Snowy, Unpaved road, etc)

• Driving in mountain road, ascent/descent

• Repetition of short distance driving

• More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F) .

• Police, Taxi, Commercial type operation or trailer towing, etc

1. Remove the drain plug (A) and reinstall the drain plug after draining ATF totally.

Drain plug tightening torque:

34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~32.6 l

The gasket of the drain plug use new one.

2. Fill the oil about 5 liters.

3. Check the oil level. (Refer to Oil level check procedure.)

-ft)

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Components and Components Location

)

Components (1

Components (2

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1. Automatic transaxle case

2. Low & reverse brake piston

3. Low & reverse brake return spring

4. Snap ring

5. Front annulus gear assembly

6. Front planetary gear assembly

7. Front sun gear assembly

8. Bearing

9. Middle sun gear assembly

10. Middle & rear planetary gear assembly

11. Rear annulus gear assembly

22. Under drive brake chamber

23. Under drive brake piston

24. Under drive brake spring

25. Snap ring

26. Under drive brake disc set

27. Snap ring

28. Under drive brake hub assembly

29. Thrust washer

30. 35R & 2/6 hub assembly

31. Thrust bearing

32. 2/6 brake disc set

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13. Low & reverse brake disc set

14. Snap ring

15. One way clutch assembly

16. Snap ring

17. Overdrive clutch assembly

18. Rear cover assembly

19. Valve body assembly

20. Valve body cover

21.Under drive brake retainer

Components Locatio

34. Thrust washer

35. Oil pump assembly

36. Transfer driven gear assembly

37. Differential assembly

38. Oil filter assembly

39. Parking sprag

40. Parking sprag shaft & spring

41. Support shaft

42. Parking load guide

1. Converter housing

2. Shift cable bracket

3. Automatic transaxle case

4. Rear cover

5. Valve body cover

6. Manual control lever

7. Air breather hose

8. Inhibitor switch

9. Solenoid valve connector

Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair procedures

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1. Remove the following items;

A. Air duct (A) and engine cover (B). (Refer to "Intake and Exhaust system" in EM group.)

B. Air cleaner assembly (C). (Refer to "Intake and Exhaust system" in EM group.)

C. Battery and battery tray (D). (Refer to "Charging system" in EE group.)

2. Dissconnect the solenoid valve connector (A) and inhibitor switch connector (B).

3. Remove the shift cable (C) after removing the nut (A) and the bolt (B).

ightening torque:

(A) 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 l (B) 14.7 ~21.6 N.m(1.5 ~2.2 kgf.m, 10.9 ~15.9 l

4. Remove the ground line after removing the bolt (A).

-ft)

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5. Disconnect the hose (B) after removing the automatic transaxle fluid cooler hose clamp (A).

6. Remove the wiring bracket installation bolt (A).

7. Remove the automatic transaxle upper mounting bolt (A-2ea) and the starter motor mounting bolt (B-2ea).

ightening torque:

(A) 42.2 ~ 54.0 N.m (4.3 ~5.5 kgf.m, 31.1 ~ 39.8 l (B) 49.0 ~ 63.7 N.m (5.0 ~6.5 kgf.m, 36.2 ~ 47.0 l

8. Remove the cowl top cover or wiper motor. (Refer to "Windshield Wiper/Washer" in BE group.)

9. Remove the cowl complete assembly panel(A).

-ft)

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10. Using the engine support fixture (Support SST No.: 09200-2S000, Beam SST No.: 09200-38001), hold the engine and

transaxle assembly safely.

11. Remove the automatic transaxle mounting support bracket bolt (A).

Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.8 lb-ft)

12. Lift the vehicle with a jack.

13. Remove the under cover (A).

14. Remove the Sub frame assembly. (Refer to "Front suspension system" in SS group.)

15. Remove the drive shaft assembly. (Refer to "Drive shaft assembly " in DS group.)

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In the case of 2WD vehicle, not remove the transfer assembly.

17. Remove the dust cover(A).

18. Remove the torque converter mounting bolt (A-4ea) with rotating the crankshaft.

Tightening torque:

45.1 ~ 52.0 N.m (4.6 ~ 5.3 kgf.m, 33.3 ~ 38.3 lb-ft)

19. Remove the automatic transaxle with a jack after removing the mounting bolt (A-4ea, B-2ea).

Tightening torque:

(A) 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft) (B) 42.2 ~ 54.0 N.m (4.3 ~5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Installatio

1. Installation is the reverse of removal.

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• Power steering fluid replacement and air bleeding (Refer to "General information" in ST group.)

• Adding automatic transaxle fluid. (Refer to "automatic transaxle system" in this group.)

• When replacing the automatic transaxle, reset the automatic transaxle's values by using the GDS.

Automatic Transaxle System > Valve Body System > Components and Components Location

Component Locatio

1. Air breather hose

2. Oil level plug

3. Valve body assembly

4. Oil temperature sensor

5. Solenoid valve

6. Valve body cover

7. Inhibitor switch

8. T/Con (VFS N/L)

9. 35R(VFS,N/H)

10. 2/6B (VFS,N/L)

11. UD(VFS,N/H)

12. OD(VFS,N/H)

13. SS-B(ON/OFF)

14. SS-A(ON/OFF)

15. LINE pressure(VFS,N/H)

16. PCV adjust screw

17. UD/B pressure

18. LR/B pressure(Low & Reverse Brake)

19. Accumulator

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Automatic Transaxle System > Valve Body System > Valve Body > Specifications

ecificatio

Piece 3pcs

Spool 20ea

Control

Solenoid valve

Pressure adjusting

Terminal type Module

Line pressure (1), Reducing pressure (2), PCV (4)

Full line pressure variable control

Torque converter release control

VFS : 6ea

ON/OFF: 2ea

7ea

Automatic Transaxle System > Valve Body System > Valve Body > Repair procedures

Remova

1. Remove the battery and the battery tray. (Refer to "Charging system" in EE group.)

2. Remove the under cover (A).

3. Replace new gasket and the plug after drining the automatic transaxle fluid by removing the drain plug.

(Refer to "Automatic transaxle system" in this group.)

4. Remove the valve body cover (A) and eyebolt (B).

ightening torque:

(A) 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l (B) 34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.6 l

The gasket of the eyebolt use new one.

Remove installation bolts in the engin room first and then remove others under the vehicle.

-ft)

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5. Remove the plate and the detend spring (A) after removing the bolt.

ightening torque:

4.5 ~ 35.3 N.m (2.5 ~ 3.6 kgf.m, 18.1 ~ 26.0 lb-ft)

6. Remove the bolt (3ea) after disconnecting the solenoid valve (B) connector and the oil temperature sensor connector

(A).

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

7. Remove the valve body assembly (A).

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

Page 27

Installatio

1. Installation is the reverse of removal.

After replacement or reinstallation procedure of the valve body assembly, must perform procedures below.

• Continue to apply liquid gasket at application points at the valve body cover with Ø2.5mm (0.0984in.) thickness.

Liquid gasket Part name : Threebond 1281B or LOCTITE FMD-546

• Adding automatic transaxle fluid. (Refer to "automatic transaxle system" in this group.)

Automatic Transaxle System > Valve Body System > Solenoid valve > Specifications

Specificatio

Item Function Piece Specification

Control pressure: 9.81~500.14kpa (0.1~5.1kgf/cm², 1.42~72.54 psi) Current value: 50~850mA Low Type, 5.1Ω

Control pressure: 500.14~9.81kpa (5.1~0.1kgf/cm², 72.54~1.42psi) Current value: 50~850mA High Type, 5.1Ω

Control pressure: 490.33kpa (5.0kgf/cm², 71.12psi) 10~11Ω Low Type

VFS

On/Off

26/B

T/Con

Line pressure

control

35R

UD OD

SS-A SS-B

Solenoid Valve Operation Table

SS-A SS-B

N, P ●●●

1 ΔΔ●

2 ●●●

3 ●●

4 ●

5 ●●

UD-VFS OD-VFS 35R-VFS 26-VFS

N/H N/H N/H N/L

Page 28

L ●●

R ●●●

Automatic Transaxle System > Valve Body System > Solenoid valve > Repair procedures

Remova

1. Remove the battery and the battery tray. (Refer to "Charging system" in EE group.)

2. Remove the under cover (A).

3. Replace new gasket and the plug after drining the automatic transaxle fluid by removing the drain plug.

(Refer to "Automatic transaxle system" in this group.)

4. Remove the valve cover (A) and eyebolt (B).

ightening torque:

(A) 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l (B) 34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.6 l

The gasket of the eyebolt use new one.

Remove installation bolts in the engin room first and then remove others under the vehicle.

5. Remove the bolt (3ea) after disconnecting the solenoid valve connector (B) and the oil temperature sensor connector

(A).

-ft)

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

Page 29

6. Remove the solenoid valve (A) after removing the solenoid support.

When installing, apply the ATF oil or White Vaseline to the O-ring not to be damaged.

Installatio

1. Installation is the reverse of removal.

After replacement or reinstallation procedure of the valve body assembly, must perform procedures below.

• Continue to apply liquid gasket at application points at the valve body cover with Ø2.5mm (0.0984in.) thickness.

Liquid gasket Part name : Threebond 1281B or LOCTITE FMD-546

• Adding automaticmatic transaxle fluid. (Refer to "automaticmatic transaxle system" in this group.)

Automatic Transaxle System > Automatic Transaxle Control System > Components and Components Location

Components Locatio

Page 30

1. Input speed sensor

2. Output speed sensor

3. Solenoid valve connector

4. Oil temperature sensor

5. Valve body assembly

6. Solenoid valve

7. Inhibitor switch

Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Components and Components Location

Component

Page 31

1. Shift lever knob

2. Shift lever assembly

3. Control cable assembly

4. Shift lever assembly(AT side)

Automatic Transaxle System > Automatic Transaxle Control System > Shift Lever > Repair procedures

Remova

1. Pull the gear knob (A) in the directionof the "F" and remove it, and then remove the console upper cover (B). (Refer to

"Interior" in BD group)

Page 32

2. Remove the center console assembly. (Refer to "Interior" in BD group.)

3. Take off the clip (A) and the clamp (B) and then remove the shift cable (C).

4. Disconnect sports mode connector (A).

5. Remove the shift lever assembly (B) by removing the bolts (A-4ea).

ightening torque:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 l

6. Remove the shift cable assembly in the vehicle after removing the nuts (B) and the retainer (A).

ightening torque:

-ft)

Page 33

7. Remove the cable from the bracket at transaxle assembly side (Refer to "Automatic Transaxle" in this group).

8. Remove the shift cable at cabin room.

Inspectio

1. Check the damage and operation of the control cable.

2. Check the damage of the boot.

3. Check the damage and corrosion of the bushing.

4. Check the damage or weakening of the spring.

Adjustment

Adjusting method for T/M control cable

1. Set room side lever and T/M side lever to "N" position.

2. Connect room side lever and shift cable.

3. Push cable to "F" direction shown to eliminate FREE PLAY.

4. Tighten adjusting nut (A).

ightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 l

-ft)

5. After adjusting according Check to be sure that this part operates surely at each range of T/M side corresponding to

each position of room lever.

Installatio

1. Installation is the reverse of removal.

Set room side lever and T/M side lever to "N" position.

Page 34

Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Control

Module (TCM) > Schematic Diagrams

1. TCM connector and terminal functio

2. TCM terminal functio

Connector [CHG-A]

Pin Description Pin Description

1-31-

2 - 32 Shift solenoid F(SS-B)

3 Pressure control solenoid A(VFS-LINE) 33 Shift solenoid E(SS-A)

4 Torque Converter Clutch solenoid (VFS-T/Con) 34 Ground (Power 1)

5 Shift solenoid C(35R_VFS) 35 Ground (Power 2)

6 Input speed sensor power 36 Sports mode down switch

7 Output speed sensor power 37 Sports mode up switch

8 Input speed sensor signal 38 Sports mode Select switch

9 Output speed sensor signal 39 -

10 - 40 Inhibitor switch signal (S1)

11 - 41 -

12 - 42 -

13 - 43 -

14 - 44 -

15 - 45 -

16 - 46 -

17 Shift solenoid A(VFS-UD) 47 Solenoid supply power 1

18 Shift solenoid B(VFS-26) 48 Solenoid supply power 2

19 Shift lock solenoid 49 TCM Input power 1 (For solenoid)

20 Shift solenoid D(VFS-OD) 50 TCM Input power 2 (For solenoid)

21 - 51 Reserved

22 Rear lamp relay 52 Reserved

23 - 53 Oil temperature sensor (-)

24 Start relay 54 Oil temperature sensor (+)

25 Inhibitor switch signal (S2) 55 -

26 Inhibitor switch signal (S3) 56 -

27 Inhibitor switch signal (S4) 57 -

28 - 58 -

29 - 59 -

Page 35

Connector [CHG-K]

Pin Description Pin Description

1 Power ground 31 Power ground

2 Battery power (B+) 32 Battery power (B+)

3 Power ground 33 CAN High

4 Battery power (B+) 34 CAN Low

3. TCM Terminal input/ output signa

Connector [CHG-A]

Pin Description Condition Type Level Test result

Pressure control solenoid A

5 Shift solenoid C(35R_VFS) Output

6 Input speed sensor power

7 Output speed sensor power

8 Input speed sensor signal

(VFS-LINE)

Torque Converter Clutch

solenoid (VFS-T/Con)

OFF 0.3 V

High

Low

Output

Power 0V/7.5V

Input 0.7V/1.4V

0V/Battery voltage level

9V < Battery voltage level < 16V

0V/Battery voltage level

9V < Battery voltage level < 16V

0V/Battery voltage level

9V < Battery voltage level < 16V

7.5V

High

9 Output speed sensor signal

Low

10 -

11 -

12 -

13 -

14 -

15 -

16 -

Input 0.7V/1.4V

0V/Battery voltage level

Page 36

17 Shift solenoid A(VFS-UD) Output

Power supply : V_SOL2

0V/Battery voltage level

18 Shift solenoid B(VFS-26) Output

19 Shift lock solenoid

20 Shift solenoid D(VFS-OD) Output

21 -

22 Rear lamp relay

23 -

24 Start relay

25 Inhibitor switch signal (S2)

26 Inhibitor switch signal (S3)

27 Inhibitor switch signal (S4)

28 -

29 -

30 -

31 -

32 Shift solenoid F(SS-B)

33 Shift solenoid E(SS-A)

34 Ground (Power 1) Ground 0V 0V

35 Ground (Power 2) Ground 0V 0V

36 Sports mode down switch

37 Sports mode up switch

38 Sports mode select switch

39 -

40 Inhibitor switch signal (S1)

High

Low 9V < Battery voltage level < 16V 0.3 V

R ON

Other 9V < Battery voltage level < 16V Battery voltage level

High

Low 9V < Battery voltage level < 16V 0.3 V

High

Low 9V < Battery voltage level < 16V 0.3 V

High

Low 9V < Battery voltage level < 16V 0.3 V

High

Low 9V < Battery voltage level < 16V 0.3 V

High

Low 9V < Battery voltage level < 16V 0.3 V

High

Low 9V < Battery voltage level < 16V 0.3 V

Down ON

Other 9V < Battery voltage level < 16V Battery voltage level

Up ON

Other 9V < Battery voltage level < 16V Battery voltage level

Sport mode

Other 9V < Battery voltage level < 16V Battery voltage level

High

Low 9V < Battery voltage level < 16V 0.3 V

Output

Input

Output

Input

9V < Battery voltage level < 16V

Power supply : V_SOL2

0V/Battery voltage level Battery voltage level

0V/Battery voltage level

9V < Battery voltage level < 16V

Power supply : V_SOL1

0V/Battery voltage level 0.3V

0V/Battery voltage level Battery voltage level

0V/Battery voltage level 0.3V

0V/Battery voltage level Battery voltage level

Page 37

42 -

43 -

44 -

45 -

46 -

47 Solenoid supply power 1

48 Solenoid supply power 2

51 -

52 -

53 Oil temperature sensor (-) Ground 0V 0V

54 Oil temperature sensor (+)

54 -

55 -

56 -

57 -

58 -

59 -

60 -

TCM Input power 1

(For solenoid)

TCM Input power 2

(For solenoid)

Power

OFF 9V < Battery voltage level < 16V 0.3 V

Power

OFF 9V < Battery voltage level < 16V 0.3 V

Power

Input 0V/3.3V

OFF 0.3V

0V/Battery voltage level Battery voltage level

Battery voltage level

9V < Battery voltage level < 16V

Battery voltage level

9V < Battery voltage level < 16V

Sensor level

(0V~3.3V)

Connector [CHG-K]

Pin Description Condition Type Level Test result

1 Power ground Ground 0V 0V

2 Battery power (B+)

3 Power ground Ground 0V 0V

4 Battery power (B+)

5 Power ground Ground 0V 0V

6 Battery power (B+) Power

Power

OFF 9V < Battery voltage level < 16V 0.3 V

Power

OFF 9V < Battery voltage level < 16V 0.3 V

0V/Battery voltage level Battery voltage level

Battery voltage level

9V < Battery voltage level < 16V

Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Control Module (TCM) > Repair procedures

Replacement

Page 38

In the case of the vehicle equipped with immobilizer or button engine start system, perform "Key Teaching" procedure

together (Refer to "Immobilizer" or "Button Engine Start System in BE group).

1. Turn ignition switch OFF and disconnect the negative (-) battery cable.

2. Disconnect the TCM Connector (A).

3. Remove the battery (Refer to "Chargin System" in EE group).

4. Remove the mounting bolts (A) and nut (B), and then remove the TCM (C).

ightening torque:

(A) 21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 l (B) 9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.9 l

-ft)

TCM Problem Inspection Procedure

1. TEST TCM GROUND CIRCUIT: Measure resistance between TCM and chassis ground using the backside of TCM

harness connector as TCM side check point. If the problem is found, repair it.

Specification: Below 1Ω

2. TEST TCM CONNECTOR: Disconnect the TCM connector and visually check the ground terminals on TCM side and

harness side for bent pins or poor contact pressure. If the problem is found, repair it.

3. If problem is not found in Step 1 and 2, the TCM could be faulty. If so, make sure there were no DTC's before swapping

the TCM with a new one, and then check the vehicle again. If DTC's were found, examine this first before swapping TCM.

4. RE-TEST THE ORIGINAL TCM: Install the original TCM (may be broken) into a known-good vehicle and check the

vehicle. If the problem occurs again, replace the original TCM with a new one. If problem does not occur, this is intermittent problem (Refer to “Intermittent Problem Inspection Procedure” in Basic Inspection Procedure).

Adjustment

TCM Learning

When shift shock is occurred or parts related with the transaxle are replaced, TCM learning should be performed.

Page 39

• Transaxle assembly replacement

• TCM replacement

• TCM upgrading

1. TCM learning condition

- ATF temperature: 60~115°C (140~239°F)

2. TCM learning procedure A. Stop learning

Repeat the below shift pattern four times or more with stepping on the brake.

B. Driving learning

1. Drive the vehicle through all gears at D range. Drive from stop to 1st to 2nd to 3rd to 4th to 5th to 6th with keeping fixed throttle open.

2. Down shift from 6th to 5th, 5th to 4th, 4th to 3rd, 3rd to 2nd, 2nd to 1st.

3. Repeat the above driving pattern four times or more.

Up-shift throttle open : 15~30%

Automatic Transaxle System > Automatic Transaxle Control System > Input Speed Sensor > Description and Operation

Descriptio

- Integrated one unit for input & output speed sensor

- Differential current type (low: 7mA, high: 14mA)

- Failsafe: 4th gear hold (D), 2nd ~ 4th manual shift (S)

Automatic Transaxle System > Automatic Transaxle Control System > Input Speed Sensor > Specifications

Specificatio

Item Specification

Type Hall Effect Sensor, 2pins (Power: 9V, Signal)

Operation condition -40 ~150°C [-40 ~ 302°F]

Sensor length 52.7~52.9mm (2.0748~2.0827in.)

Air gap 0.95~1.65mm (0.0374~0.0650in.)

Automatic Transaxle System > Automatic Transaxle Control System > Input Speed Sensor > Repair procedures

Remova

1. Remove the battery and the battery tray. (Refer to "Charging system" in EE group.)

2. Remove the under cover (A).

Page 40

3. Replace new gasket and the plug after drining the automatic transaxle fluid by removing the drain plug.

(Refer to "Automatic transaxle system" in this group.)

4. Remove the valve body cover (A) and eyebolt (B).

ightening torque:

(A) 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l (B) 34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.6 l

The gasket of the eyebolt use new one.

Remove installation bolts in the engin room first and then remove others under the vehicle.

-ft)

5. Remove the plate and the detend spring (A) after removing the bolt.

ightening torque:

4.5 ~ 35.3 N.m (2.5 ~ 3.6 kgf.m, 18.1 ~ 26.0 lb-ft)

6. Remove the bolt (3ea) after disconnecting the solenoid valve connector (A) and the oil temperature sensor connector (B).

Page 41

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

Be careful not to damage the harness lock connector.

7. Remove the valve body assembly (A).

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

8. Disconnect the input & output speed sensor connector(A).

9. Remove the input & output speed sensor (B) after removing the bolts(2ea).

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

Page 42

Installatio

1. Installation is the reverse of removal.

After replacement or reinstallation procedure of the valve body assembly, must perform procedures below.

• Continue to apply liquid gasket at application points at the valve body cover with Ø2.5mm (0.0984in.) thickness.

Liquid gasket Part name : Threebond 1281B or LOCTITE FMD-546

• Adding automaticmatic transaxle fluid. (Refer to "automaticmatic transaxle system" in this group.)

Automatic Transaxle System > Automatic Transaxle Control System > Output Speed Sensor > Description and Operation

Descriptio

- Integrated one unit for input & output speed sensor

- Differential current type (low: 7mA, high: 14mA)

- Failsafe: 4th gear hold (D), 2nd ~ 4th manual shift (S)

Automatic Transaxle System > Automatic Transaxle Control System > Output Speed Sensor > Specifications

Specificatio

Item Specification

Type

Operation condition -40 ~150°C [-40 ~ 302°F]

Sensor length 33.6~33.8mm (1.3228~1.3307in.)

Air gap 0.25~1.9mm (0.0098~0.0748in.)

Hall Effect Sensor, 2pins

(Power: 9V, Signal)

Automatic Transaxle System > Automatic Transaxle Control System > Output Speed Sensor > Repair procedures

Remova

Page 43

2. Remove the under cover (A).

3. Replace new gasket and the plug after drining the automatic transaxle fluid by removing the drain plug. (Refer to "Automatic transaxle system" in this group.)

4. Remove the valve body cover (A) and eyebolt (B).

ightening torque:

(A) 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l (B) 34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.6 l

The gasket of the eyebolt use new one.

-ft)

Remove installation bolts in the engin room first and then remove others under the vehicle.

5. Remove the plate and the detend spring (A) after removing the bolt.

ightening torque:

4.5 ~ 35.3 N.m (2.5 ~ 3.6 kgf.m, 18.1 ~ 26.0 lb-ft)

6. Remove the bolt (3ea) after disconnecting the solenoid valve connector (A) and the oil temperature sensor connector

Page 44

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

Be careful not to damage the harness lock connector.

7. Remove the valve body assembly (A).

-ft)

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

8. Disconnect the input & output speed sensor connector (A).

9. Remove the input & output speed sensor (B) after removing the bolts(2ea).

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

Page 45

Installatio

1. Installation is the reverse of removal.

After replacement or reinstallation procedure of the valve body assembly, must perform procedures below.

• Continue to apply liquid gasket at application points at the valve body cover with Ø2.5mm (0.0984in.) thickness.

Liquid gasket Part name : Threebond 1281B or LOCTITE FMD-546

• Adding automaticmatic transaxle fluid. (Refer to "automaticmatic transaxle system" in this group.)

Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Oil Temperature Sensor > Specifications

Specificatio

Item Specification

Type Negative Thermal Coefficient Type

Operation temperature -40~165°C [-40~329°F]

Resistance 4.81kΩ~39 Ω

Failsafe Oil temperature set to default value [80°C(176°F)]

Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Oil Temperature Sensor > Repair procedures

Remova

1. Remove the battery and the battery tray. (Refer to "Charging system" in EE group.)

2. Remove the under cover (A).

Page 46

3. Replace new gasket and the plug after drining the automatic transaxle fluid by removing the drain plug.

(Refer to "Automatic transaxle system" in this group.)

4. Remove the valve body cover (A) and eyebolt (B).

ightening torque:

(A) 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l (B) 34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.6 l

The gasket of the eyebolt use new one.

Remove installation bolts in the engin room first and then remove others under the vehicle.

-ft)

5. Disconnect the oil temperature sensor connector (A).

6. Remove the oil temperature sensor (A) after removing a bolt.

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

Page 47

Be careful not to damage the harness lock connector.

Installatio

1. Installation is the reverse of removal.

After replacement or reinstallation procedure of the valve body assembly, must perform procedures below.

• Continue to apply liquid gasket at application points at the valve body cover with Ø2.5mm (0.0984in.) thickness.

Liquid gasket Part name : Threebond 1281B or LOCTITE FMD-546

• Adding automaticmatic transaxle fluid. (Refer to "automaticmatic transaxle system" in this group.)

Automatic Transaxle System > Automatic Transaxle Control System > Inhibiter Switch > Description and Operation

Descriptio

Item Specification

Type Combination of output signals from 4 terminals

Power supply 12V

Range detection 7-position (P, R, N, D, X, Y, Z)

Failsafe 1st, 2nd gear is prohibited.

Automatic Transaxle System > Automatic Transaxle Control System > Inhibiter Switch > Repair procedures

Remova

1. Set room side lever and T/M side lever to "N" position.

2. Remove the battery and the battery tray. (Refer to "Charging system" in EE group.)

3. Remove the air cleaner assembly. (Refer to "Intake manifold" in EM group.)

4. Remove the shift cable mounting nut (B).

5. Disconnect the inhibitor switch connector (A).

Page 48

6. Remove the manual control lever (A) and the washer (B) after removing a nut (C).

When installing, fix the manual control lever and the inhibitor switch with Ø5mm (0.1969in.) fixing jig. And then tighten the inhibitor assembly mounting bolts.

7. Remove the inhibitor assembly (A) after removing the bolts (2ea).

ightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 l

-ft)

When installing, tighten the inhibitor assembly mounting bolt lightly.

Installatio

1. Installation is the reverse of removal.

Page 49

Body (Interior and Exterior) > General Information > Specifications

Specification

Items Specification

Hood Type Rear hinged, front opening type

Front Door Construction Front hinged, full door construction

Regulator system Wire-drum type

Locking system Pin-fork system

Rear Door Construction Front hinged, full door construction

Regulator system Wire-drum type

Locking system Pin-fork system

Tail Gate Type Front hinged, gas lifter type

Seat Belts Front 3 point type with Emergency Locking Retractor (E.L.R)

Rear 3 point type with Emergency Locking Retractor (E.L.R)

2 point type

Tightening Torque

Items N.m Kgf.m lb-ft

Front andrear doors Door hinge to body 34.3 ~ 41.2 3.5 ~ 4.2 25.3 ~ 30.4

Door hinge to door 9.8 ~ 19.6 1.0 ~ 2.0 7.2 ~ 14.5

Door checker to door 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3

Door checker to body 16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9

Door glass mounting bolt 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

Outside handle base mounting bolt 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

Door channel mounting nuts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

Latch mounting bolts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

Door module mounting bolts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

Door striker mounting bolts 8.8 ~ 13.7 0.9 ~ 1.4 6.5 ~ 10.1

Tail gate Tail gate hinge to tail gate 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Tail gate hinge to body 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Tail gate latch mounting bolts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

Tail gate striker mounting bolts 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Hood Hood hinge to body 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Hood hinge to hood 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Hood latch to body 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

Seat Front seat mounting bolts 44.1 ~ 58.8 4.5 ~ 6.0 32.5 ~ 43.4

Front seat frame mounting bolts 44.1 ~ 58.8 4.5 ~ 6.0 32.5 ~ 43.4

Rear seat mounting bolts 44.1 ~ 58.8 4.5 ~ 6.0 32.5 ~ 43.4

Seat belt Height adjuster mounting bolts 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

Front seat belt upper anchor mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

Front seat belt lower anchor mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

Front seat belt retractor mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

Rear seat belt lower anchor mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

Page 50

Seat belt buckle mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

Quarter fixed glass Quarter fixed glass mounting nuts 3.9 ~ 4.4 0.4 ~ 0.45 2.9 ~ 3.3

Outside rearview mirror Outside rearview mirror mounting nuts 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

Panoramaroof Panoramaroof mounting nuts 19.6 ~ 29.4 2.0 ~ 3.0 14.5 ~ 21.7

Panoramaroof mounting bolts 19.6 ~ 29.4 2.0 ~ 3.0 14.5 ~ 21.7

Panoramaroof earthing mounting bolt 10.8 ~ 13.7 1.1 ~ 1.4 8.0 ~ 10.1

Body (Interior and Exterior) > General Information > Special Service Tools

ecial Tools

Tool (Number and name) Illustration Use

09793-21000 Door hinge adjusting wrench

Adjustment, removal and installationof the door hinge

09800-21000 Ornament remover

09853-31000 Headliner clip remover

09861-31100 Sealant cut-out tool

09861-31200 Sealant cutting blade

Trim removal

Headliner clip removal

Cutting windshield sealant (Use with 09861-31200)

Cutting windshield sealant (Use with 09861-31100)

09861-31000 Windshield molding remover

09880-4F000 Hog ring clip installer

Windshield molding removal

Hog ring clip Installation

Page 51

09840-1M100 Air vent remover

Air vent removal

09816-2P100 Power silent cutting tool

09816-2P110 Air power tool

09816-2P121 Cutter-1

09816-2P122 Cutter-2

Tool box for removing panorama sunroof

Air tool for installing blade

Blade for removing the front and side area of panorama sunroof (This blade has a inclination to push upward.)

09816-2P123 Cutter-3

09816-2P124 Cutter-4

09816-2P130 Cutter-10

Blade for removing the front and side area of panorama sunroof (This blade has a inclination to push downward.)

Blade for removing the edge area of panorama sunroof

Page 52

09816-2S100

Fixed glass fixture

Installation the fixed glass

Body (Interior and Exterior) > General Information > Troubleshooting

Troubleshootin

Symptom Suspect Area Remedy

Water leaks from panoramaroof Deteriorated roof lid weatherstrip Replace

Excessive roof lid-to-body clearance andImproperly fitted weatherstrip

Wind noise around sunroof Loose or deformed deflector, gapsIn body

work

Noise heard when opening/ closing panoramaroof

Motor runs but sunroof does not move or moves only partially

Noise in motor (clutch slipping noise from motor when sunroof is fully opened or closed is not an unusual noise

Door glass fails to operateUp and Down

Door does not open or closecompletely

Hood does not open or close completely

Water leak through windshield and rear window

Foreign particles lodged in guide rail Check drive cable and guide rails for

Loose guide rails and lid Retighten

Foreign particles lodged in guide rail Adjust or replace

Incorrect engagement of motor pinion with drive cable

Decrease in motor`s clutch slipping force

Increased sunroof sliding resistance or interference of sunroof with drive cables, weatherstrip, etc. due to maladjustment of sunroof

Incorrect engagement of motor pinion with drive cable

Worn out or damaged motor pinion bearing

Worn out or deformed drive cable Replace

Incorrect window glass installation Adjust position

Damaged or faulty regulator arm or regulator

Incorrect door installation Adjust position

Defective door check assembly Correct or replace

Door hinge requires grease Apply grease

Striker and latch not properly aligned Adjust

Incorrectly installed hood Adjust

Incorrect hood bumper height Adjust

Defective seal Fill with sealant

Defective flange Correct

Adjust

Retighten adjust or replace

foreign particles

Check pinion installation and retighten motor

Replace motor assembly

Correct or replace

Page 53

Body (Interior and Exterior) > Body Dimensions > General Information

Genera

1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual.

Measurement Metho

Projected Dimensions

1. These are the dimensions measured when the measurement points are projected into the reference plane, and are the reference dimensions used for body alterations.

2. If the length of the tracking gauge probes is adjustable, make the measurement by lengthening one probe by the amount equivalent to the difference in height of the two surfaces.

Actual-Measurement Dimensions

1. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use if a tracking gauge is used for measurement.

2. Measure by first adjusting both probes to the same length (A=A').

Check the probes and gauge itself to make sure there is no free play.

Measurement Point

1. Measurements should be taken at the hole center.

Page 54

Body (Interior and Exterior) > Body Dimensions > Front Body > Body Repair

y A

Front bod

Page 55

Front body B

Page 56

Page 57

Front body C

Page 58

Page 59

Body (Interior and Exterior) > Body Dimensions > Side Body > Body Repair

y A

Side bod

Page 60

Page 61

Side body B

Page 62

Page 63

Body (Interior and Exterior) > Body Dimensions > Interior > Body Repair

Interior

Page 64

Page 65

Interior B

Page 66

Page 67

Interior C

Page 68

Page 69

Interior D

Page 70

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Body (Interior and Exterior) > Body Dimensions > Rear Body > Body Repair

Page 72

Page 73

Body (Interior and Exterior) > Body Dimensions > Under Body > Body Repair

Pro

ected Dimension

Page 74

Page 75

Actual- Measurement Dimension

Page 76

Page 77

Body (Interior and Exterior) > Exterior > Fender > Repair procedures

Replacement

• When removing and installing the hood, an assistant is necessary.

• Be careful not to damage the hood and body.

• When removing the clips, use a clip remover.

1. Remove the front bumper. (Refer to the BD group – “Front Bunper” )

2. Loosen the mud guard mounting screws.

Page 78

3. After loosening the mounting screws and clips, then remove the side sill garnish (A).

4. After loosening the mounting screws, then remove the front bumper side mounting bracket (A).

5. Using a screwdriver, remove the fender side cover (B).

6. After loosening the mounting bolts, then remove the fender (A).

Page 79

Body (Interior and Exterior) > Exterior > Hood > Repair procedures

lacement

Hood Assembly Replacement

• When removing and installing the hood, an assistant is necessary.

• Take care not to damaged the hood and body.

• When removing the clips, use a clip remover.

1. Loosen the hood hinge (A) mounting bolts, remove the hood (B).

Tightening torque:

21.6 ~ 26.5 N.m (2.2 ~ 2.7 kgf.m 15.9 ~ 19.5 lb-ft )

2. Installation is the reverse of removal.

• Make sure the hood locks/ unlocks and opens/ closes properly.

• Adjust the hood alignment.

Hood Insulator Pad Replacement

• Take care not to scratch the hood panel.

1. Using a clip remover, remove the clips.

2. Remove the hood insulator pad (A).

Page 80

3. Installation is the reverse of removal.

• Replace any damaged clips.

Hood Seal Weatherstrip Replacement

1. Detach the clips, then remove the hood weatherstrip(A).

• Take care not to scratch the hood seal weatherstrip.

2. Installation is the reverse of removal.

• Replace any damaged clips.

Hood Weatherstrip Replacement

1. Remove the hood weatherstrip (A).

2. Installation is the reverse of removal.

Hood Latch Release Handle Replacement

1. Remove the hood release handle (A).

Page 81

2. Installation is the reverse of removal.

• Make sure the hood latch release cable is connected properly.

• Make sure the hood locks/unlocks and opens/closes properly.

Hood Latch Replacement

1. Loosen the hood latch (A) mounting bolts.

2. Disconnect the hood latch cable (B) and release cable (C).

Tightening torque :

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

3. Installation is the reverse of removal.

• Make sure the hood latch release cable is connected properly.

• Make sure the door locks/unlocks and opens/closes properly.

• Adjust the latch alignment.

Adjustment

Adjust Hoo

1. After loosening the hinge (A) mounting bolt, adjust the hood (B) by moving it up or down, or right or left.

2. Adjust the hood height by turning the hood over slam bumpers (C).

Page 82

Body (Interior and Exterior) > Exterior > Tail Gate > Repair procedures

Replacement

Tail Gate Trim Replacement

• When prying with a flat-tipped screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.

• Put on gloves to protect your hands.

• Make sure the tailgate locks/unlocks and opens/closes properly.

1. Remove the upper trim(B).

2. After loosening the mounting screws, then remove the tailgate trim (C) and side trim(A).

3. Installation is the reverse of removal.

• Replace and damaged clips.

• Make sure the opens securely

Page 83

Tail Gate Latch Replacement

1. Remove the tail gate trim.

2. After loosening the mounting bolts, then remove the latch assembly (A).

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

3. Installation is the reverse of removal

• Make sure the tail gate opens properly.

Tail Gate Lift Replacement

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• Take care not to be closed the tail gate, when removing the life.

1. Using a screwdriver (A), lift the socket clip (B) up slightly on both ends of the lifter (D), and then remove the lifter from the bracket (C).

2. Push the socket of the lifter into the bracket for installation.

• Make sure the tailgate locks/unlocks and opens/closes properly.

Tail Gate weatherstrip Replacement

• Do not apply sealant to the body.

1. Remove the tail gate weatherstrip (A).

2. Installation is the reverse of removal.

• Install the weatherstrip aligned with canter line (B).

Adjustment

1. Check that the door and body edges are parallel.

2. After loosening the tailgate hinge (A) mounting bolt, adjust the tailgate by moving it up or down, or right or left.

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4. Make sure the trunk lid opers and locks securely.

Body (Interior and Exterior) > Exterior > Front Door > Components and Components Location

Com

onents

Page 86

1.Door inside handle housing

2. Door trim

3. Door belt inner weatherstrip

4. Door screen

5. Door module

6. Quadrant inner cover

7. Door panel

8. Door belt outside weatherstrip

9. Door side weatherstrip

10. Body side weatherstrip

11. Door hinge

Body (Interior and Exterior) > Exterior > Front Door > Repair procedures

lacement

Front Door Trim Replacement

• When prying with a flat-tipped screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.

• Put on gloves to protect your hands.

1. Using a screwdriver or remover, remove the quadrant inner cover (A).

2. Disconnect the tweeter speaker connector (B).

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3. After loosening the mounting screws, then remove the door inside handle housing (B).

4. After loosening the mounting screws, then remove the door trim (A).

5. Push the lock pin (A), disconnect the connectors (B).

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6. Installation is the reverse of removal.

• Make sure connectors are connected properly and each rod is connected securely.

• Make sure the door locks/unlocks and opens/closes properly.

• Replace and damaged clips.

Inside Handle Replacement

1. Remove the door trim.

2. Remove the door screen (A).

• Replace ant damaged screen.

3. After loosening the mounting screws, then remove the inside handle (A).

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5. Installation is the reverse of removal.

• Make sure the door locks/unlocks and opens/closes properly.

• Replace ant damaged clips.

Glass Replacement

1. Remove the front door trim.

2. Remove the door screen.

3. Remove the glass mounting plug hole.

• Take care not to drop to glass and scratch the glass surface.

4. Carefully adjust the glass (B) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1kgf.m 5.1 ~ 8.0 lb-ft )

5. Installation is the reverse of removal.

• Roll the glass up and down to see if it move freely without binding.

• Adjust glass position as needed.

• Replace ant damaged clips.

• Make sure the door locks/unlocks and opens/closes properly.

Speaker Replacement

1. Remove the door trim.

2. Remove the door screen.

3. After loosening the mounting screws, remove the speaker (B).

4. Disconnect the speaker connector (A).

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5. Installation is the reverse of removal.

• Use sheet metal screws to secure the speaker.

• Replace ant damaged clips.

• Make sure connectors are connected properly and each rod is connected securely.

• Make sure the door locks/unlocks and opens/closes properly.

Power Window Motor Replacement

1. Remove the door trim.

2. Remove the door screen.

3. Disconnect the connector (A), then loosen the mounting screws.

4. Remove the power window motor (B).

5. Installation is the reverse of removal.

• Grease should be applied to areas where there is rotational parts and springs.

• Roll the glass up and down to see if it move freely without binding.

• Replace ant damaged clips.

• Make sure the door locks/unlocks and opens/closes properly.

Door Module Assembly Replacement

1. Remove the following parts :

A. Front door trim B. Door screen.

C. Window glass D. Outside handle

2. Loosen the outside handle base mounting screw (A).

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3. Disconnect the outside handle connector (A).

4. Loosen the module mounting bolts.

5. Loosen the latch mounting nuts, remove the module (A).

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

6. Disconnect the connector (A) and clip.

7. Installation is the reverse of removal.

• The area of whole parts should be applied with sufficient grease.

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• Make sure the door locks/unlocks and opens/closes properly.

• Replace ant damaged clips.

Outside Handle Replacement

1. Remove the cap, loosen the mounting bolt.

2. Remove the outside handle cover (A).

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1kgf.m 5.1 ~ 8.0 lb-ft )

3. Remove the outside handle (A), by sliding it rearward.

4. Disconnect the outside handle connector (A).

5. Installation is the reverse the removal.

• Make sure the door locks/unlocks and opens/closes properly.

Adjustment

Glass Adjustment

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• Check the glass run channel for damage or deterioration, and replace them necessary.

1. Remove the door trim.

2. Remove the door screen.

3. Carefully move the glass (A) until the glass mounting bolt are visible, then loosen them.

4. Check that the glass moves smoothly.

Door Striker Adjustment

Make sure the door latches securely without slamming it. If necessary adjust the striker (A): The striker nuts are fixed. The striker can be fine adjusted up or down, and in or out.

1. Loosen the screws (B) just enough for the striker to move.

Tightening torque (B):

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft )

2. Tap on the striker with a plastic hammer to adjust the striker. The striker will not move much, but will give some adjustment.

3. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck.

Door Position Adjustment

• After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the mounting bolts.

1. Place the vehicle on a firm, level surface when adjusting the doors.

2. Check that the door and body edges are parallel.

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3. Adjust at the hinges (A):

A. Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush with the body. B. Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize

the gaps.

C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.

(Special service tool : 09793-21000)

Tightening torque : (B) : 34.3 ~ 41.2 N.m (3.4 ~ 4.2 kgf.m, 25.3 ~ 30.4 lb-ft) (C) : 9.8 ~ 19.6 N.m (1.0 ~ 2.0 kgf.m, 7.2 ~ 14.5 lb-ft)

4. Grease the pivot portions of the hinges indicated.

5. Check for water leaks.

Body (Interior and Exterior) > Exterior > Rear Door > Components and Components Location

Component

Page 95

1. Door inside handle housing

2. Door trim

3. Door belt inner weatherstrip

4. Door screen

5. Door module

6. Door panel

7. Door delta inner cover

8. Door belt outside weatherstrip

9. Door delta molding cover

10. Door side weatherstrip

11. Body side weatherstrip

12. Door hinge

Body (Interior and Exterior) > Exterior > Rear Door > Repair procedures

Replacement

Door Trim Replacement

• When prying with a flat-tipped screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.

• Put on gloves to protect your hands.

1. Using a screwdriver or remover, remove the delta inner cover (A).

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2. After loosening the mounting screw, then remove the door inside handle housing (B).

3. Loosen the mounting screws, then remove the door trim (A).

4. Push the lock pin (A), disconnect the power window connector (B).

5. Installation is the reverse of removal.

• Make sure connectors are connected properly and each rod is connected securely.

• Make sure the door locks/unlocks and opens/closes properly.

• Replace ant damaged clips.

Inside Handle Replacement

1. Remove the door trim.

2. Remove the door screen (A).

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3. After loosening the mounting screws, then remove the inside handle (A).

4. Disconnect the inside handle cable (B).

5. Installation is the reverse of removal.

• Make sure the door locks/unlocks and opens/closes properly.

Glass Replacement

1. Remove the following parts. A. Door trim B. Door screen

C. Door belt weatherstrip

D. Door delta molding cover

2. After loosening the mounting nuts, then remove the rear channel (A).

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1kgf.m 5.1 ~ 8.0 lb-ft )

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3. Remove the glass mounting plug hole.

• Using the door switch to align the mounting hole with the hole on the door glass.

• If it is impossible, align the hole by hand after removing the motor.

• Be careful not to drop to glass and scratch the glass surface.

4. Carefully adjust the glass (B) until you can see the bolts, then loosen them. Separate the glass from the glass run and

carefully pull the glass out through the window slot.

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1kgf.m 5.1 ~ 8.0 lb-ft )

5. Installation is the reverse the removal.

A. Roll the glass up down to see if it move freely without binding B. Adjust the position of the glass as needed.

C. Make sure the door locks/unlocks and opens/closes properly. D. Replace ant damaged clips

Speaker Replacement

1. Remove the door trim.

2. Disconnect the speaker connector (A).

3. After loosening the mounting screws, then remove the speaker (B).

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4. Installation is the reverse of removal.

• Use sheet metal screws to secure the speaker.

• Make sure the door locks/unlocks and opens/closes properly.

• Make sure the connector is connected properly.

Power Window Motor Replacement

1. Remove the door trim.

2. Remove the door screen.

3. Disconnect the connector (A)

4. After loosening the mounting screws, then remove the power window motor (B).

5. Installation is the reverse of removal.

• Grease should be applied to areas where there is rotational parts and springs.

• Roll the glass up and down to see if it move freely without binding.

• Make sure the door locks/unlocks and opens/closes properly.

Outside Handle Replacement

1. Disconnect cap, loosen the mounting bolt.

2. Remove the handle cover (A).

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0 lb-ft )

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3. Remove the outside handle (A), by sliding it rearward.

4. Installation is the reverse of removal.

• Roll the glass up and down to see if it move freely without binding.

• Make sure the door locks/unlocks and opens/closes properly.

Door Module Assembly Replacement

1. Remove the following parts. A. Door trim

B. Door screen

C. Window glass D. Outside handle

2. Loosen the mounting screw (A).

3. After loosening the mounting nuts, then remove the rear channel (A).

Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)