Introduction
Introduction
SERVICE INFORMATION
INTRODUCTION
WARNING This indicates that injuries to you or other people may happen.
This indicates that damage to repairing components may
CAUTION
happen.
ENVIRONMENTAL PROTECTION Dispose of the waste materials according to local regulations.
Provide additional information to help you with the service
HINT
operations.
2. Service procedure
Illustrations attached with the service procedure are used to identify components, show the assembling
relevance of parts, and explain the visual check for parts. Removal and installation procedures are
explained in words.
Service procedures include:
Detailed removal and installation instruction
Illustration
Torque specifications
Specifications
Sometimes, the illustrations of similar models are used. In this case, minor details may be different from
the actual vehicle.
3. Diagnosis procedure
Diagnosis procedures are divided as below:
Diagnostic Trouble Code (DTC)
DTC is an important hint when troubleshooting is difficult to simulate. The malfunction can be
diagnosed quickly and accurately by performing the specified DTC diagnosis and check.
Problem symptoms table
Malfunction locations can be determined quickly by troubleshooting in accordance with the symptom
type.
4. Specifications
This manual categorizes specifications as below:
Torque specifications
Clearance specifications
Capacity specifications
Preparation
1. Preparation for vehicle service
02
6 3
RT21020010
Lifter Center
Front
RT21020020
02
Attachment
RT21020030
Service Operation
1. How to use fasteners
WARNING
Using incorrect fasteners may cause damage to components. Injury and death may occur without
observing the instructions below.
The reference values of fasteners and torque specifications in this service manual use metric unit.
Recycling all the fasteners (nuts, bolts, etc.) during maintenance and service operation is important for
assembly.
If it's impossible to recycle fasteners, be sure to use other fasteners with the same specifications.
2. Remove parts
When repairing malfunction, try to determine the cause.
Before starting work, the parts or sub-assemblies that
have to be removed and replaced should be confirmed
first. After removing parts, block all holes and ports to
prevent foreign objects from entering.
02
RT21020040
3. Disassemble components
If disassembly procedures are complicated and multiple parts need to be disassembled, make sure that
disassembly methods won't affect the performance or appearance of parts. Identify each part for assembly.
4. Check parts
After removal, check each part for deformation, damage or other problems.
5. Arrange parts
Carefully arrange all the disassembled parts to make assembly easier.
Always separately arrange the replaced parts and reusable parts, and make marks on them.
6. Clean parts
Make a thorough and careful cleaning for reusable parts.
WARNING
Blowing out the dirt or other particles with compressed air may hurt your eyes. Be sure to wear goggles
during operation.
7. Assemble components
When assembling parts, always strictly use the standard values (tightening torque and clearance value,
etc.).
If following parts need to be replaced, replace them with
new ones.
Oil Seal Cotter Pin
Oil seal
Gasket
O-ring Gasket Nylon Nut
Lock washer
Cotter pin
O-ring Lock Washer
Nylon nut
RT21020050
RT21020060
13.Vise
When using vise, install protective plates on the jaws of
vise to prevent parts from being damaged.
RT21020080
14.Dynamometer
When testing vehicle on the dynamometer, pay attention to the followings:
Place a fan in front of the vehicle. It's best to use a fan of which the power changes in proportion to the
vehicle speed.
Connect an exhaust gas ventilator.
WARNING
02 Exhaust gas may cause injury and death. There is odorless, colorless Carbon Oxide (CO) in the exhaust
gas. People will faint and get poisoned after inhaling it.
VEHICLE INFORMATION
Vehicle Identification Information
1. Vehicle Identification Number (VIN)
VIN is located on the upper left part of instrument panel
on driver side, and can be seen from the outside through * *
windshield. LVTDBXXXXXXXXXXXX
02
RT21020090
RT21020100
1 2 3 4 5 6
RT21020110
No. Definition
1 World Manufacturer Identifier
2 Vehicle Features
3 Accuracy Check Digit
4 Model Year
02 5 Production Plant
6 Sequential Number
LVTDBXXXXXXXXXXXX
1870 kg 1- 1012 kg
2- 971 kg
RT21020120
3. Engine number
The engine number is stamped on the engine block
under the exhaust manifold.
* * *
SQR484F XXXXXXXXX
02
RT21020130
4. Transmission number
The transmission number (for MT model) is stamped on
the transmission case.
QR525MHE
XXXXXXXXX
RT21020140
RT21020150
Symbols
The symbols below are instrument cluster display symbols and some international standard symbols.
+ -
1 2 3 4 5 6
02 EPC
7 8 9 10 11 12
13 14 15 16 17 18
OFF
19 20 21 22 23 24
25 26 27 28 29 30
ཽ⪔⊳䖜
If communication is normal when the tester is connected
to another vehicle, inspect the DLC on the original
02
vehicle.
If communication is still not possible when the tester is
connected to another vehicle, the tester itself is probably
defective.
RT21020160
Step Description
1 Obtain detailed information when electrical malfunction occurs.
Operate affected system, and perform a road test as necessary.
2 Confirm malfunction parameter.
If it is impossible to duplicate malfunction, refer to "Electrical Malfunction Simulation Test".
Collect proper diagnosis materials, which includes:
Circuit Diagram
System Schematic Diagram
3 Relevant Chapter in Service Manual
Service Bulletin
Perform diagnosis according to the mastered system operation knowledge and customer's
feedback.
Check if there is any bonding, loose connector or damaged wire harness in the system.
4 Determine related circuits and components, and diagnose according to the circuit diagram and
wire harness layout diagram.
5 Repair circuit and replace component as necessary.
Operate system in all modes. Confirm that system can operate normally in all conditions.
6 Confirm that you have not inadvertently created new malfunctions during your diagnosis or
repair steps.
Slightly Vibrate
Slightly Wiggle
RT21020170
HINT:
When connector is exposed to humid environment, a layer of corrosive film may form on its terminals.
With the connector connected, this condition may not be found by visual check.If an intermittent
malfunction occurs, it may be caused by corrosion. It is recommended that the terminals of relevant
connectors in the system should be checked and cleaned after disconnecting the connectors.
b. Sensors and relays.
Slightly vibrate the sensors and relays that you want to check in the system. The sensors or relays that
are loose or poorly installed may be found through this test.
c. Engine compartment
There are many reasons for the electrical malfunction that occurred due to vehicle vibration, and it is
necessary to check the following conditions:
- Connectors are not installed correctly.
- Wire harness is not long enough, so it is extended when engine is vibrating or shaking.
- Wire harness hangs over the bracket or movable components.
- Ground wire is loose, dirty or corrosive.
02 - Wire harness is too close to the high temperature components.
To inspect the components under the engine hood, first confirm that the ground connection is in
perfect condition (refer to the grounding inspection described below). First confirm that the system is
correctly grounded. Then slightly vibrate the wire harness or components as previously instructed to
check if the connection is loose. Refer to the circuit diagram to check the continuity of wire harness.
d. Backside of instrument panel
Improper wire clamping will cause the wire harnesses to be entangled when installing accessories.
The vibration of vehicle will cause the wire harnesses near the bracket or mounting screw to wind
excessively.
When vehicle vibrates, unclamped or loose wire harness will be stuck in the seat components (such
as slide guide). When wire harness passes through the underside of mounting area, check if it is
damaged or stuck.
2. Thermosensitive test
In hot weather or after the vehicle is parked for a short time, the user may worry about the vehicle
condition. At this time, it is necessary to perform thermosensitive test.
Perform test by heating components with a heat gun or equivalent.
CAUTION
3. Freezing test
If malfunction disappears after warming up the vehicle in winter, it may be caused by freeze of some parts
in the wire harness/electrical system. Use the following two methods to check this condition:
Method 1: Put vehicle outdoors overnight. Make sure that the temperature is low enough to duplicate the
malfunction. Perform a quick and thorough diagnosis on the component that may be affected in the
morning.
Method 2: Put suspected part in refrigerating room and wait until it is frozen. Reinstall the component to
vehicle and check if malfunction reoccurs. If malfunction occurs, repair or replace the component.
4. Leakage test
Malfunction may occur only during high humidity or in
rainy or snowy weather. In this case, malfunction may
occur due to water entering electrical parts. Leakage can
be checked by spraying water to vehicle (similar to car
wash).
RT21020180
5. Load test
Malfunction occurs only when electrical device is turned
on. Turn on the electrical equipment (A/C, rear window
defogger, radio, fog light, etc.) one by one and determine
the relationship between electrical equipment and
malfunction. Confirm the malfunction by a load test.
02
RT21020190
RT21020200
Disconnecting the battery cable will delete the clock, audio and DTC records. Therefore, it is necessary to
confirm these records before disconnecting the cable.
Never connect the electrodes of battery terminals reversely.
Only install components that meet the vehicle specifications.
1. Inspect input and output conditions of components and their functions before replacing control module.
When disconnecting components:
- Do not use excessive force when disconnecting connector.
- If connector is installed by tightening bolt, loosen mounting bolt and then disconnect the connector
by hand.
When connecting components:
- Make sure that terminals are not bent or damaged, and then connect it correctly before installing
connector.
- Tighten the mounting bolt until the painted area of connector is flush with the surface when installing
connector by tightening bolt.
Never drop or hit the control module to prevent excessive impact.
Note that the condensation is not formed on control module due to extreme change of temperature and
keep it free from water drop or rain. If water is found on the control module, dry it thoroughly and then
install it to vehicle.
Be careful not to allow fluid to adhere to the control module connector.
Avoid cleaning the control module with volatile fluid.
02
When using digital multimeter, be careful not to get
the testing probes to contact with each other to result
in a short circuit. Avoid damaging the battery due to
short circuit in power transistor inside the control
module.
RT21020210
Use specified test adapter to check the input and output signals of control module.
2. Check fuse
Check that fuse wire is connected.
Good Blown
RT21020220
Terminal
02
Deformation
Slightly Pull
RT21020230
CIRCUIT INFORMATION
How to Read Circuit Diagram
1. Connector symbols
Most of the connector symbols in circuit diagrams
indicate the terminal side.
02 Terminal Side
Harness Side
RT21020240
2. Option splices
Option splice is indicated by diamonds (solid line), and marked with pin number inside.
E-106 E-106
16 15 8 4
E-106 E-106
SENSOR SENSOR
E-106 E-106
RT21020260
EXAMPLE
[1] BATTERY
IGNITION SWITCH
ON OR START [14]
ENGINE
[15]
[2] EF05
30A
COMPARTMENT
FUSE AND RELAY BOX 02
E-049
D3
[3] A
A11 A13
2 3
INSTRUMENT
[4] MAIN
RF14 PANEL FUSE [16]
RELAY AND RELAY BOX
10A
1 5 I-004
RF19
15A
A4 A3 A1 A2 [13]
VR
SENSOR
I-003
MT CVT [12]
1 2
G
B
I-013
BW
RW
[8]
10 13 11 3 4
1 CONTROL
MODULE
I-001
MOTOR 7 8 9
[7] M E-011
GR
TO BACKLIGHT [18]
V
POWER SUPPLY
2 1 6
SWITCH
[9]
B
I-009
[11] TO CAN
[19] SYSTEM
[10]
E-014 3 5
[20]
I-006
D1 D2 D3 D4 D5
1 2 3 4 5 6 7 8 9 10 11 12 13 A16 A15 A14 A9 A8 A7
14 15 16 17 18 19 20 21 22 23 24 25 26
A6 A5 A4
A13 A12 A11 A10
A3 A2 A1
[21] D6 D7 D8 D9 D10 D11 D12
E-049
I-001 I-004 [22] W
W W
1 2 3 4 5 6 7 8 4 5 6 1 2
1 2 1 2 3
9 10 11 12 13 14 15 16
I-009 I-003
I-013
E-011 W W
W
Gr ET21020000
ABBREVIATION TABLE
Abbreviation Table
Term Abbreviation
Anti-lock Brake System ABS
02 Acceleration Sensor AES
Accelerator Pedal Position Sensor APS
Automatic Temperature Control ATC
Automatic Transmission Fluid ATF
Body Control Module BCM
Brake Pressure Sensor BPS
Camshaft Position Sensor CMPS
Clutch Pedal Position Switch CPP Switch
Crankshaft Position Sensor CKPS
Data Link Connector DLC
Diagnostic Trouble Code DTC
Engine Control Module ECM
Engine Coolant Temperature ECT
Engine Speed RPM
Evaporative Emission EVAP
Evaporative Emission Canister EVAP Canister
Evaporative Emission System EVAP System
Exhaust Gas Recirculation Valve EGR Valve
Front Left Wheel Speed Sensor FLS
Front Right Wheel Speed Sensor FRS
Rear Left Wheel Speed Sensor RLS
Rear Right Wheel Speed Sensor RRS
Ground GND
Heated Oxygen Sensor O2S
Idle Air Control IAC
Intake Temperature IAT
Ignition IGN
Ignition Control IC
Immobilizer Control Module ICM
Injector INJ
Input Shaft Speed Sensor ISS Sensor
Knock Sensor KS
Manifold Absolute Pressure MAP
Term Abbreviation
Mass Air Flow MAF
Malfunction Indicator Light MIL
Oil Pressure Switch OPS
Output Shaft Speed Sensor OSS Sensor
Positive Crankcase Ventilation Valve PCV Valve
02
Power Supply PWR
Supplemental Restraints System SRS
Throttle Position Sensor TPS
Transmission Control Module TCM
Turbine Speed Sensor TSS
Vehicle Identification Number VIN
Vehicle Speed Sensor VSS