International A/S & Parts
Quality Problem & Trouble Shooting Team
2001.08.10
Subject Noise from alternator in CD operating
Models Chairman
Condition
In audio operating, abnormal peak noise sounds from speaker due to alternator revolution.
Main cause
Dsp wire which is linked to the engine room fuse No.33, is too long, so this wire is exposed to
any electrical noise signal.
Improvement
The DSP wire route is changed to connect it to trunk fuse No.41.
In-line date : Apr.15,2001 - VIN 17254
Rework procedure
1. Disconnect the Battery (-) terminal
2. Disconnect 16 pin connector of DSP
3. Take out No 1 pin from the connector, then wrap up the pin to deelectric : No1 pin :0.5 sq,BlW
4. Fix the modification wire to the trunk fuse box like picture.
5. Inset the end of the wire to the No.1 position of the DSP connector
6. Replace the Fue 30A (No 53) with 7.5A
7. Connect the battery (-) terminal
International A/S & Parts
Quality Problem & Trouble Shooting Team
2001.08.10
Subject Noise from alternator in CD operating
Models Chairman
Separate DSP connector
Rework wire
Fix point
Operation code and Labor time
Operation code Work discription Labor time
5509990 Audio wire modification 0.3 M/H
Confirm
If not solved this noise, check belows
1. Check the condensor into junction box under the seat
2. Check the condensor in the engine room C.E box
3. Finally replace the alternator
Shifting problem of transmission
Oct.17,2001
1. Model : Chairman 600S
2. Phenomenon : Occur the shift delay or shift shock on the driving
3. Cause
⑴ Different (or unmatching) type between engine ECU and TCU
⑵ Installed TCU is not coded
4. Failure code descriptions on the scan-tool diagnosis
▼ In case of 'VDO 32' engine ECU and 'Bosch' type TCU
Vehicle On the scan-tool diagnosis On the sensor signal
Diagnosis point
condition Failure code Description value diagnosis
CAN communication
Engine ECU side 26
failure : TCU
TCU is not coded Other equipment - Normalcy
All values from engine
TCU side
ECU are indicated zero
CAN communication
Engine ECU side 26
failure : TCU
TCU is nomalcy CAN : EMS
TCU side E36/E37/E39
information failure
ABS/ASR side 31 EMS (engine) failure
5. Work procedure
⑴ Check the type of vehicle and engine (ECU)
⑵ Install and coding the TCU that is match for the vehicle and engine (ECU) type
6. Part number of TCU and coding parameter by engine ECU type
Engine ECU type Part number of TCU Coding parameter for TCU
Bosch 32 020 545 24 32 e03eA0y07
VDO 32/28 020 545 25 32 e03eA0y09
VDO 23 36610 11000 (BTRA) e03eA0y02 or e03eA0y13
TCU is not coded case. e03eA0yFF
International A/S & Parts
Quality Problem & Trouble Shooting Team
2001.08.10
Subject Noise and vibration when to steer the wheel
Models Chairman 400S
Condition
Noise and vibration happen when to steer the wheel toward full right or left hand
Main cause
Only belt tendioner was installed on the CM400 model limitedly.
Now the belt shober is installed together with the tensioner.
Rework
If the above problem occurs, the present belt tensioner and shober
Defect Part number Present part number
Tensioner : 111 200 07 70
111 200 12 70
shober : 111 200 02 14
Caution
When to tighten the belt tensioner pulley, do not tighten over torque.
If tighten too much, interference occurs between the tensioner fixing point and
mooving part.
Quality Problem & Trouble Shooting International A/S & Parts
Team
Subject ABS/ABD WARNING LAMP ON
Models CHAIRMAN
Phenomenon
- The ABS/ABD warning lamp always on
Main Cause
- The Switch a-stop lamp is damaged.
; The stop lamp switch is improper connection becasue the terminal of switch inside is broken.
stop lamp switch
Work procedure
- Replace it with new one.
Improvement history :
- The thickness of terminal which is inside of switch is increased.
; 0.11 -> 0.2mm
- Applied date : Apr.14,2000.
- Applied VIN No. : 10300~
International A/S & Parts
Quality Problem & Trouble Shooting Team
2001.08.10
Subject Function of rain sensing
Models Chairman
1. Service flow
Check to install condition for windshield glass and
coupler
Check to power-up
function
Check to instant wipe
function
Check to wiper
function
Check to high speed for
wiper
Check to irregular
acting
Check to self diagnostic
function
1) Check to install condition for windshield glass and coupler
- Check to abnormal wear, scratch and defection with windshield portion into the sensing area.
- Check to wear status of glass to using self diagnostic function.
- Check to coupler.
2) Function of power-up
- Wiper act 1 time when the ignition switch turn on during auto mode ( or the wiper switch turn auto mode
from off position during ignition on) then remove the function after 5 minutes.
: Recognized to driver whether is the wiper function acting.
- Wiper work when it's rain. (wiper speed depend on rain rate)
- Wiper work during 5 minutes after stop rain.
- If the function doesn't work, check to unit 8 and low wiper unit. (place fuse box in engine room).
3) Function of instant wipe.
- The wiper works 1time when knob of combi-switch turns each 1stage.
It's recognized raining.
- If the function doesn't work, check to variable resistor of terminal 5.
(1stage("S"):50㏀, 2stage:37.5㏀, 3stage:25㏀, 4stage:12.5㏀,5stage("F"):0㏀)
4) Function of washer & wiper.
- The wiper work and spread washer water when you press the washer switch.
- If the function fault, check to terminal 6.
* Function of MTST : When you press washer switch short time(0.2~0.6sec), the washer water spread
and the wiper work 1time.
5) Check to max. speed operation.
- The wiper work max. speed when it's heavy rain.
- If the function fault, check to terminal no.1(low speed) and no. 2(high speed).
6) Irregular operation.
- Check to separate sensor, and install condition of sensor cover.
- Check to customer know how to use the combi switch.
- Check to wear of wiper blade.
7) Function of self diagnostic.
- Place the auto position of combi switch, turn 1step the knob of variable resistor from fast position to slow position
: If the wiper operate, the windshield glass occur wear or scratch. When sensing is problem, replace the windshie
When sensing is problem, replace the windshield glass, or check to sensor and installation of coupler.
- After above step, turn more 1step the knob of variable resistor.
: When the wiper operate, replace the sensor.
he knob of variable resistor from fast position to slow position.
ar or scratch. When sensing is problem, replace the windshield,
International A/S & Parts
Quality Problem & Trouble Shooting Team
2001.08.10
Subject Service procedure of wind noise
Models Chairman
1. Condition
1) Occur the wind noise at upper side of door wind glass during the driving.
- Bias the wind glass towards front side when the glass go up.
- The wind glass insert that the glass bias when the glass gone up.
2) Check process.
- Attached the paper tape with wind glass out side and run rubber
2. Cause
- There are clearance between the glass run and carrier plate.
3. Check to regulator
1) Adjust of regulator
- Loose the mounting bolt of regulator. (upper 2 points, lower 2 points)
- Tight the mounting bolt of regulator while the regulator press direction of door latch mounting.
- Check to whether the glass bias during going up and down.
2) Check to regulator
- Check to clearance of carrier plate when the fixed piece separate from wind glass.
(Available to mounting condition of wind glass)
* Figure
Nut 2EA
(upper side)
Carrier
plate
Nut 2EA
Occur of (low side)
noise
4. Others
- The wind noise occurs a variety of cause. After accurate investigation, treat service work.
International A/S & Parts
Quality Problem & Trouble Shooting Team
2001.08.10
Subject Intermittent shortage of trunk fuse
Models Chairman
1. Condition
- Fault parts when fuse shortage
: Fault of truck opening
Fault of fuel door opening
Fault of center door lock switch of driver side
2. Fault position
Interference of wiring.
("B" pillar-RH side, wiring connector of rear door)
3. Cause
- Interfere with mounting bolt of door checker and wiring of terminal no 2 at C371 connector.
4. Work procedure
- Tape work by insulated tape at shortage portion.
- Exchange connector and wiring.
- Attached the sponge at mounting bolt end portion of checker.
