Manual de Servicio Chevrolet Matiz 800 y 1L - Spark

CAPÍTULO 1
MOTOR
Motor 800cc: Número de motor............................................................... 5
Motor 800cc: Especificaciones de rendimiento de motor........................ 6
Motor 800cc: Información general........................................................... 7
Motor 800cc: Embrague y caja de cambios manual................................ 8
Motor 800cc: Lubricantes y fluidos recomendados.................................. 9
Motor 800cc: Vista lateral del motor....................................................... 10
Motor 800cc: Vista frontal del motor....................................................... 11
Motor 800cc: Montaje del motor............................................................. 12
Motor 800cc: Ajuste de holgura de válvulas........................................... 13
Motor 800cc: Ajuste del tiempo de ignición............................................ 14
Motor 800cc: Bandas.............................................................................. 15
Motor 800cc: Instalación de la banda de tiempo.................................... 16
Motor 800cc: Ajuste de la banda de tiempo........................................... 17
Motor 800cc: Chequeo de la presión de compresión............................. 18
Motor 800cc: Lubricación del motor....................................................... 19
Motor 800cc: Bomba de combustible..................................................... 21
Motor 800cc: Circuito de la bomba de combustible y filtro..................... 22
Motor 800cc: Cánister o filtro de carón activo........................................ 24
Motor 800cc: Sistema de escape........................................................... 26
Motor 800cc: Sistema de enfriamiento del motor................................... 27
Motor 1000cc: Número de motor............................................................. 31

Motor 1000cc: Especificaciones.............................................................. 32
Motor 1000cc: Vista general.................................................................... 35
Motor 1000cc: Instalación de banda de tiempo....................................... 36
Motor 1000cc: Ajuste de la banda de tiempo.......................................... 37
Motor 1000cc:Chequeo de la holgura de válvulas.................................. 38
Motor 1000cc: Ajuste de holgura de válvulas......................................... 39
Motor 1000cc: Bandas............................................................................ 40
Motor 1000cc: Lubricación...................................................................... 41
Motor 1000cc: Admisión......................................................................... 43
Motor 1000cc: Escape............................................................................ 44
Motor 1000cc: Sistema de enfriamiento.................................................. 45
Motor 1000cc: Bomba de combustible.................................................... 47
Motor 1000cc: Cánister o filtro de carbón............................................... 48
Table of Contents 1-3
M-Car:
Engine Repair
0.8L Engine: Engine Number .................................................................... 5
0.8L engine: Vehicle Performance Engine Specification ........................... 6
Instructor Guide
0.8L engine: General Information .............................................................. 7
0.8L engine: Clutch & Manual Transaxel ................................................... 8
0.8L engine: Recommended Fluids & Lubricant ........................................ 9
0.8L engine: Engine Side View ............................................................... 10
0.8L engine: Engine Front View ............................................................... 11
0.8L engine: Engine Mounting ................................................................. 12
0.8L engine: Valve-Clearance Adjustment ............................................... 13
0.8L engine: Ignition Timing Adjustment .................................................. 14
0.8L engine: Belt ...................................................................................... 15
0.8L engine: Timing Belt Installation ........................................................ 16
0.8L engine: Timing Belt Adjustment ....................................................... 17
0.8L engine: Compression Pressure Check ............................................ 18
0.8L engine: Engine Lubrication .............................................................. 19
0.8L engine: Fuel Pump .......................................................................... 21
0.8L engine: Fuel Pump Circuit and Fuel Filter ....................................... 22
0.8L engine: Evaporative Emissions Canister ......................................... 24
0.8L Engine: Exhaust System .................................................................. 26
0.8L Engine: Cooling System .................................................................. 27
1.0L Engine: Engine Number .................................................................. 31
1.0L Engine: Specifications ..................................................................... 32
1.0L Engine: Engine Overview ................................................................ 35 ER-1
1.0L Engine: Timing Belt Installation ....................................................... 36
1.0L engine: Timing Belt Adjustment ....................................................... 37
1.0L Engine: Valve Clearance Check ...................................................... 38
1.0L Engine: Valve Clearance Adjustment .............................................. 39
1.0L Engine: Belt ..................................................................................... 40
1.0L Engine: Lubrication .......................................................................... 41
1.0L Engine: Intake .................................................................................. 43
1.0L Engine: Exhaust .............................................................................. 44
1.0L Engine: Cooling System Overview .................................................. 45
1.0L Engine: Fuel pump .......................................................................... 47
Evaporative Emission Canister ............................................................... 48
EngineRepair: Lab 1................................................................................ 49
EngineRepair: Lab 2................................................................................ 50
Engine Repair: Test Questions ................................................................ 51
rev 02
0.8L Engine: Engine Number 1-5
M-Car:
Engine Repair
F 8 C V 012345
Instructor Guide
Engine Serial Number
000001 - 999999
Cam Mechanism
V : SOHC 2V Fuel Injection
T : SOHC 4V Fuel Injection
S : SOHC 4V Feed Back Carburetor
Design Sequence
Ex : A-B-C-D
Displacement
8 : 0.8L
9 : 1.0L
Engine Type
F : 4 Cycle 3 Cylinder In Line
ER-2
rev 02
1-6 0.8L engine: Vehicle Performance Engine
M-Car: Specification
Engine Repair
Instructor Guide Vehicle Performance

Application 0.8L SOHC MT
Maximun speed (km/h) 144 (89.5 mph)
Maximun Power.kw (ps)/rpm 37.5(51.0)/6000(50 hp)
Maximum torque. kg.m

7.0(50.6)/4600
(lb.ft)/rpm
Engine Specification
Application 0.8L SOHC
Engine type Overhead Cam L3
Bore(mm) × stroke(mm) 68.5 x 72.0 (2.7in x 2.8 in)
Total displacement (cc) 796 (49 cu in)
Compression ratio 9.3 : 1
Euro stage II /
Application Euro stage III
Leaded
Direct ignition High Energy
Ignition type
system Ignition(HEI)
Ignition timing
5° 10°
(BTDC)
Ignition sequence 1-3-2 1-3-2
Application Unleaded Leaded
Golden : BPR5EY-11 Golden : BPR5EY

Spark plug type Champion : RN9YC4 Champion : RN9YC
Bosch : WR8DCX Bosch : WR8DC
1.1 mm
: BPR5EY-11,
Spark plug gap RN9YC4 0.8 mm
1.2 mm
: WR8DCX
rev 02
0.8L engine: General Information 1-7
M-Car:
Engine Repair
Lubrication
Application 0.8L SOHC Instructor Guide
Lubricating Type Forced Feed
Oil Pump Type Rotary (Trochoid)
Oil Filter Type Full Flow
Oil Pan Capacity with Oil Filter 2.7 L (2.9 qts)
Cooling
Cooling Type Forced Water Circulation
Radiator Type Cross Flow
Water Pump Type Centrifugal
Thermostat Type Pellet Type
Coolant Capacity 3.8 L (4 qts)
Electric
Battery 12V-35AH, 275CCA
Generator 65A
Starter 0.8 KW
Fuel
Fuel Delivery Type MPI
Fuel Pump Type Electric Motor Pump
Fuel Filter Type Cartridge

35 L / 38 L (Euro stage III)
Fuel Capacity
(9.2 gal/ 10 gal)
rev 02
1-8 0.8L engine: Recommended Fluids & Lubricant
M-Car:
Engine Repair
Recommended Fluid and Lubricant
Instructor Guide
Usage Capacity Fluid/Lubricant
API SJ Grade SAE 10W-30

2.7 L
Engine oil (Cold area : SAE 5W-30)
(2.9 qts)
(Hot area : SAE15W-40/10W-30)
3.8 L Water + Ethylene glycol base antifreeze

Engine coolant
(4 qts) (Year round coolant ; 50:50 mixing ratio)
0.45 L
Brake Fluid DOT-3 / DOT-4
(0.47 qts)
1.0 L
Power steering DEXRON II / DEXRON III
(1.1 qts)
2.1 L
Manual transaxle SAE 75W-85 (GL-4)
(2.2 qts)
Multi-purpose grease
Manual transaxle shift linkage As Required
(Requirement : NLGI No. 1 or 2)
Key lock cylinder As Required Silicone Lubricant
Clutch linkage pivot points As Required Grease
Parking brake cable As Required Grease
Hood latch assembly As Required Grease
Hood and Door hinges

Fuel door hinge As Required Spray grease
Rear compartment lid hinges
Weatherstrips As Required Silicone grease
rev 02
0.8L engine: Engine Side View 1-9
M-Car:
Engine Repair
Instructor Guide
ER-3
0.8 Liter
The 1.0 SOHC Engine is similar to the 0.8L Except that it is a four-cylinder
engine.
rev 02
1-10 0.8L engine: Engine Front View
M-Car:
Engine Repair
Instructor Guide
ER-4
0.8 Liter
rev 02
0.8L engine: Engine Mounting 1-11
M-Car:
Engine Repair
Instructor Guide
RH
LH
RR
ER-5
RH
FH
rev 02
1-12 0.8L engine: Valve-Clearance Adjustment
M-Car:
Engine Repair
Instructor Guide
ER-6
Measuring Valve Clearance
Cylinder Number
No. 1 Cyinder Condition 1 2 3
IN O O
Compression Top Dead Center
EX O O
IN O
Exhaust Top Dead Center
EX O
Application Value
IN 0.15 ± 0.02 / 0.006 ± 0.0007

Cold
EX 0.32 ± 0.02 / 0.013 ± 0.0007
Valve Clearance (mm)/(in)
IN 0.25 ± 0.02 / 0.010 ± 0.0007
Hot
EX 0.42 ± 0.02 / 0.017 ± 0.0007
rev 02
0.8L engine: Ignition Timing Adjustment 1-13
M-Car:
Engine Repair
ECE 83 and Euro II
Instructor Guide
1. Warm up engine, jump terminals 2. Check ignition timing with

A and C of the DLC timing light.
ER-7
3. Ignition Timing: 10° before TDC 4. If ignition timing needs adjustment,

use timing light to turn distributor
body appropriately.
rev 02
1-14 0.8L engine: Belt
M-Car:
Engine Repair
Instructor Guide
Belt Installation
Length
Item Type
(mm/in)
Alternator 635 / 25"

ER-8 V Belt
Power Steering Belt 665 / 26.2"
A/C Belt 735 / 28.9"

Rib Belt
A/C Belt + Power Steering Belt 910 / 35.8"
rev 02
0.8L engine: Timing Belt Installation 1-15
M-Car:
Engine Repair
Instructor Guide
ER-9
Model Part number ID Length Maintenance
851.6 mm I : 40,000 km / 24,800 mi

M-Car 12761A78B00 White (A-475)
33.6" R : 80,000 km / 49,700 mi
NOTE: I = Inspection; R = Replacement

(Inspect for belt fraying, cracking or broken belt teeth.)
rev 02
1-16 0.8L engine: Timing Belt Adjustment
M-Car:
Engine Repair
1. Align the both marks on
the cam sprocket and the
Instructor Guide cover

the crankshaft sprocket
and the cover
ER-10
3. Install the timing belt

4. Tighten tensioner bolt
rev 02
0.8L engine: Compression Pressure Check 1-17
M-Car:
Engine Repair
Instructor Guide
Standard 12,5
Pressure
Limit 12~13
(kg/cm2)
Difference between cylinders 1.0 or less
1. Warm up until normal operating temperature

2. Stop the engine
3. Remove all spark plugs and lead wires of distributors
4. Disconnect the intake air cleaner elbow hose
5. Put the compression gage in the spark plug hole
6. Disengage the clutch and depress accelerator all the way down
7. Crank the engine and read the highest pressure measure
rev 02
1-18 0.8L engine: Engine Lubrication
M-Car:
Engine Repair
Instructor Guide
Lubrication Circuit
Application Specification Remarks
TICO :
SAE 10W-30
Engine Oil SAE 10W-30
API SJ
API SE
Capacity of Oil 2.7 L (2.85 qt) Including Oil Filter
- Normal Condition : Every 10,000 km (6,214 mi)

Maintenance
- Severe Condition : Every 5,000 km (3,107 mi)
rev 02
0.8L engine: Engine Lubrication 1-19
M-Car:
Engine Repair
Instructor Guide
Engine Oil Pressure Check
Application Specification
- Idle : 1 ± 0.2 kg/cm² (14 psi)

Oil Pump Pressure - 2000 rpm : 2.5~3.0 kg/cm² (36-43 psi)
- Relief : 3.4 ± 0.4 kg/cm² (104-139 psi)
Oil Pressure Switch Tightening Torque 120-160 kg cm (104 - 139 lb/in)
rev 02
1-20 0.8L engine: Fuel Pump
M-Car:
Engine Repair
The fuel pump is located inside the fuel
tank.
Instructor Guide
It operates when the ECM receives
reference pulses from the crank sensor.
Fuel Pressure
Regulator If there is no reference pulse while the
ignition is ON or the engine stops running,
the ECM will turn OFF the fuel pump 2
seconds later.
The fuel pump delivers fuel to the fuel rail
and injectors. The fuel pressure regulator
controls the fuel system pressure, which is
located on the fuel pump assembly inside
Fuel Pressure the fuel tank. The fuel pump contains a
Regulator relief valve and a check valve for safety.
Resistance(W)
Fuel quantity
Max Min
Full 33.3 L (8.8 gal) 43 37
3/4 26.2 L (6.9 gal) 70 64
ER-11 1/2 19.1 L (5.0 gal) 102.5 96.5
1/4 12.1 L (3.2 gal) 153 147
Warning lamp 5.0 L (1.3 gal) 286 280
1. Fuel Pressure Regulator 3. Overflow Valve

2. Spring 4. Diaphragm
NOTE: Fuel Pressure = 3.6 - 3.8 kg/cm² (51-54 psi)

Fuel filter maintenance : Every 3 years or 45,000 km
(28,000 mi)(installed on the fuel tank)
rev 02
0.8L engine: Fuel Pump Circuit and Fuel Filter 1-21
M-Car:
Engine Repair
OBD
Instructor Guide
MAIN
RELAY
FUEL PUMP
RELAY
INJECTOR
“2” Ter “2” Ter

Generator VSS
INTERTIA
SWITCH
ECM ER-12
(Sirius D3)
FUEL
PUMP
POWER
STEERING
OIL
PRESSURE O2 SENSOR
SWITCH
rev 02
1-22 0.8L engine: Fuel Pump Circuit and Fuel Filter
M-Car:
Engine Repair
Non OBD
Instructor Guide
]: ONLY UNLEADED
MAIN
RELAY
OVER SPEED
WARNING
BUZZER
INJECTOR
ER-13
ECM
(FENIX 5MR)
System
Ground
FUEL
PUMP
O2
SENSOR POWER
STEERING
OIL
PRESSURE
SWITCH
rev 02
0.8L engine: Evaporative Emissions Canister 1-23
M-Car:
Engine Repair
The evaporative emission canister is an emission control device containing
activated charcoal granules. The evaporative emission canister is used to store
fuel vapors from the fuel tank. Once certain conditions are met, the electronic Instructor Guide
control module (ECM) activates the controlled canister purge solenoid allowing
the fuel vapors to be drawn into the engine cylinders and burned.
Element: Activated Carbon
ER-14
M150
M150 II
rev 02
1-24 0.8L engine: Evaporative Emissions Canister
M-Car:
Engine Repair
Instructor Guide
ER-15
1. Evaporative Emissions Canister

2. Purge Solenoid
rev 02
0.8L Engine: Exhaust System 1-25
M-Car:
Catalytic Converter Engine Repair
The pup converter is used in addition to the conventional Three Way
Catalyst (TWC) to enhance exhaust gas purification. The pup is located Instructor Guide
just below the exhaust manifold.
The catalytic converter requires the use of unleaded fuel only or damage to
the catalyst will result. The catalytic converter is an emission control device
added to the exhaust system to reduce pollution from the exhaust.
The oxidation catalyst is coated with a catalytic material containing platinum
and palladium, which reduces the level of hydrocarbon (HC) and carbon
monoxide (CO) from the exhaust gas. The catalyst in the TWC has coatings
that contain platinum and rhodium, which further lower the level of nitrogen
oxides (NOx). The TWC converts hydrocarbons (HC), carbon monoxide (CO),
and nitrogen oxides (NOx) into carbon dioxide (CO²), nitrogen (N²) and water
vapor.
Metathesis Metathesis
Efficiency Efficiency
(%) (%)
HC
CO HC
CO
NO
Air-Fuel Mixture Temperature (ºC)
rev 02
1-26 0.8L Engine: Cooling System
M-Car:
Engine Repair
Radiator
Instructor Guide
Surge Tank Cap

Throttle
Body
ECT &
Coolant
Temperature
Thermostat Sender
0.8 L SOHC
Speed Application
ON OFF
ECT 93 90
Low
ECT Malfunction Operating at Low Speed
ECT 100 97
High
A/C Switch ON Operating at High Speed
rev 02
0.8L Engine Cooling System 1-27
M-Car:
Engine Repair
Instructor Guide
Thermostat Cooling Fan
Application Specification
Cooling Fan Size 320 mm, 14 A (12.6 in)
* Open
- start to open : 82°C (179° F)
Thermostat Operation
- Full open : 95°C (203° F)
* Close 80° C (176° F)
458 x 295 x 16 (STD) mm

Radiator size (mm) (18" x 12" x .6" (STD))
(Width x Height x Thickness) 458 x 295 x 27 (Heavy Duty) m
(18" x 12" x 1.1" (Heavy Duty))
rev 02
1-28 0.8L Engine Cooling System
M-Car:
Engine Repair
SIRIUS D3
Instructor Guide
MAIN
RELAY
COOLING FAN COOLING FAN

LOW SPEED HIGH SPEED
RELAY RELAY
COOLING FAN
LOW SPEED
RESISTOR
COOLING
FAN
LOW HI
ECM
rev 02
0.8L Engine Cooling System 1-29
M-Car:
FENIX 5MR Engine Repair
Instructor Guide
MAIN
RELAY
COOLING FAN COOLING FAN

LOW SPEED HIGH SPEED
RELAY RELAY
COOLING FAN
LOW SPEED
RESISTOR
COOLING
FAN
LOW HI
ECM
rev 02
1-30 1.0L Engine: Engine Number
M-Car:
Engine Repair
Instructor Guide B IO S I
Engine Generation Code
CAM Mechanism
S : SOHC 2V
Displacement
10 : 1.0L
Engine Family Code
B ; In Line 4 Cylinder Engine
123456 K A 2
Engine Assembly Line
2 : Changwon Assembly 2 Line
Additional Sequential
Number Code
Engine Plant Location
K: Korea
ER-16 Sequential Number
rev 02
1.0L Engine: Specifications 1-31
M-Car:
Engine Repair
Specification
Maximun speed (km/h) 152 (95 mph)
Maximun Power.kw (ps)/rpm 46.5 (63.2) / 5400 (62.4 hp)
Maximum torque. kg.m (lb.ft)/rpm 8.9 (64.4) / 4200
Engine type Overhead Cam L4
Bore(mm) × stroke(mm) 68.5 x 67.5 (2.7 x 2.6 in)
Total displacement (cc) 995 (60.7 cu in)
Compression ratio 9.3 : 1
Overlap 18
Valve timing Intake 12° BTDC / 48° ABDC
Exhaust 50° BBDC / 6° ATDC
At warm-up 850 RPM

Idle Speed
A/C ON 900 RPM
Application Unleaded Leaded
Ignition type Direct ignition system Direct ignition system
Ignition timing (BTDC) 12° 12°
Ignition sequence 1-3-4-2 1-3-4-2
Spark plug type Golden : BPR5EY-11 Golden : BPR5EY
Spark plug gap 1.1 mm (0.043 in) 0.8 mm (0.031 in)
rev 02
1-32 1.0L Engine: Specifications
M-Car:
Engine Repair
Specification
Instructor Guide Application 1.0L SOHC
Lubricating Type Forced Feed
Oil Pump Type Rotary (Trochoid)
Lubrication
Oil Filter Type Full Flow
Oil Capacity W/Oil Filter 3.5 L (3.7 qts)
Cooling Type Forced Water Circulation
Radiator Type Cross Flow
Cooling Water Pump Type Centrifugal
Thermostat Type Pellet Type
Coolant Capacity 4.0 L (4.2 qts)
Battery 12V-35AH, 275CCA
Electric Generator 65A
Starter 0.8 KW
Fuel Delivery Type MPI
Fuel Pump Type Electric Motor Pump
Fuel Fuel Filter Type Cartridge
. Plastic : 35 L (9.3 gal)
Fuel Capacity
. Steel : 38 L (Euro stage III) (10 gal)
Type Single Dry Plate
Outside Diameter 184 mm (7.2 in)
Clutch
Inside Diameter 127 mm (5 in)
Thickness 7.65 mm (0.300 in)
Maker DWMC
Model Y4M
Gear ratio
1st 3,417
2nd 1,950
M/T 3rd 1,280
4th 0,914
5th 0,758
Reverse 3,273
Final gear ratio 4,444
Oil capacity (L) 2.1 L (2.2 qts)
rev 02
1.0L Engine: Specifications 1-33
M-Car:
Engine Repair
Recommended Fluids & Lubricant
Usage Capacity Fluid/Lubricant Instructor Guide
3.5 L
Engine disassembly
(3.7 qts)
3.2 L
Oil change W/filter API SL Grade SAE 10W-30
(3.4 qts)
Engine oil (Cold area : SAE 5W-30)
3.0 L (Hot area : SAE15W-40/10W-30)
Oil change W/O filter
(3.2 qts)
Oil Level Gage 1.0 L
(Min to Max) (1.1 qts)
Water + Ethylene glycol base
4.0 L antifreeze
Engine coolant
(4.2 qts) (Year round coolant ; 50:50 mixing
ratio)
0.45 L
Brake Fluid DOT-3 / DOT-4
(0.48 qts)
1.0 L
Power steering DEXRON II / DEXRON III
(1.1 qts)
2.1 L
Manual transaxle SAE 75W-85 (GL-4)
(2.2 qts)
Multi-purpose grease
Manual transaxle shift linkage As Required
(Requirement : NLGI No. 1 or 2)
Key lock cylinder As Required Silicone Lubricant
Clutch linkage pivot points As Required Grease
Parking brake cable As Required Grease
Hood latch assembly As Required Grease
Hood and Door hinges

Fuel door hinge As Required Spray grease
Rear compartment lid hinges
Weatherstrips As Required Silicone grease
rev 02
1-34 1.0L Engine: Engine Overview
M-Car:
Engine Repair
Engine Overview
Instructor Guide
ER-17
rev 02
1.0L Engine: Timing Belt Installation 1-35
M-Car:
Engine Repair
Instructor Guide
Timing Belt Upper Front Cover

Timing Belt
Timing Belt
Tensioner ER-18
T/A CASE
Timing Belt Lower Front Cover
Model Part number ID Length Maintenance Remarks
I : 30,000 km
Matiz 1.0L 12761A78B00 White (A-475) 851.6 mm HNBR
R : 90,000 km
rev 02
1-36 1.0L engine: Timing Belt Adjustment
M-Car:
Engine Repair
the cam sprocket and the
Instructor Guide cover

the crankshaft sprocket
and the cover
ER-19
3. Install the timing belt

4. Tighten tensioner bolt
rev 02
1.0L Engine: Valve Clearance Check 1-37
M-Car:
Engine Repair
1. Remove the cylinder head cover hexagon bolts and remove the cover.
2. Turn over the crankshaft to place the No.1 cylinder on compression top
dead center. (When the camshaft sprocket notch (d) is aligned with the Instructor Guide
timing belt rear cover triangle pointer (e) and the crankshaft sprocket
point (f) is aligned with the oil pump housing point (g), the compression
top dead center is on the ignition sequence for No. 1 cylinder).
3. Check the valve clearance for No. 1 cylinder compression top dead
center.
4. If the checking for the valve clearance of No.1 cylinder compression top ER-20
dead center is on the exhaust stroke dead center, then rotate the
crankshaft 360–degrees.
(When the camshaft sprocket point (h) is aligned with the timing belt rear
cover triangle pointer (e), the exhaust top dead center is on the ignition
sequence for No. 1 cylinder.)
5. Check the valve clearance for the No. 1 cylinder exhaust top dead center.
rev 02
1-38 1.0L Engine: Valve Clearance Adjustment
M-Car:
6. Check and adjust the valve clearance (i) using thickness gauge (j). The
Engine Repair
measured value of valve clearance should meet the specified value. If not,
adjust the valve clearance.
Instructor Guide
7. When adjusting the valve clearance, loosen the adjust nut (k) and then
tighten or loosen the adjust rod (l) properly.
Important : In case of hot engine, warm up the engine until the electric
cooling fan begins to work and stop the engine to adjust the clearance within
20–30 minutes.
ER-21 No. 1 Cyinder Condition

Cylinder Number
1 2 3 4
IN O O
Compression Top Dead Center
EX O O
IN O O
Exhaust Top Dead Center
EX O O
Application 0.8L 1.0L
0.15 ± 0.02 0.15 ± 0.02

IN
(0.006 in) (0.006 in)
Cold
0.32 ± 0.02 0.20 ± 0.02
EX
(0.013 in) (0.008 in)
Valve Clearance (mm)
0.25 ± 0.02 0.25 ± 0.02
IN
(0.010 in) (0.010 in)
Hot
0.42 ± 0.02 0.3 ± 0.02
EX
(0.017 in) (0.012 in)
rev 02
1.0L Engine: Belt 1-39
M-Car:
Engine Repair
Instructor Guide
Belt Installation
Length
No. Item Type
(mm)/(in)
1 Alternator 635/25
Rib Belt
2 Power Steering Belt 665/26
ER-22
3 A/C Belt 735/29
Rib Belt
A/C Belt + Power
4 910/36
Steering Belt
rev 02
1-40 1.0L Engine: Lubrication
M-Car:
Engine Repair
Instructor Guide
ER-23
Application 0.8L SOHC 1.0L SOHC
. SAE 10W-30, API SJ . SAE 10W-30, API SL

Engine Oil
. SAE 5W-30, API SJ (Cold Area) . SAE 5W-30, API SL (Cold Area)
Oil Capacity w/Oil Filter 2.7 L (2.9 qts) 3.5L (3.7 qts)
- Normal Condition : 10,000 km / 6214 mi - Normal Condition : 15,000 km / 9321 mi

Maintenance
- Severe Condition : 5,000 km / 3107 mi - Severe Condition : 7,500 km / 4660 mi
rev 02
1.0L Engine: Lubrication 1-41
M-Car:
Engine Repair
Instructor Guide
ER-24
- Idle : 1.73 kg/cm² (25 psi)

Oil Pump Pressure
- 2000 rpm : 3.0 - 3.5 kg/cm² (43-50 psi)
Oil Pressure Switch 1.22 - 1.63 kgm

Tightening Torque (106 - 142 lb/in)
rev 02
1-42 1.0L Engine: Intake
M-Car:
Engine Repair
Instructor Guide
1. Intake Manifold
2. Exhaust Gas Recirculation
(EGR) Pipe
(EGR) Valve
4. Throttle Body Assembly
5. Air Filter Assembly
ER-25
6. Resonator
7. Snorkel

Filter Element Non Woven Fabric
Air Cleaner Capacity 6.0L (6.3 qts)

Element - Inspect : Every 15,000 km (9321 mi)
Maintenance - Replace : Every 45,000 km (27,962 mi)
Volume 1.9L (2 qts)
Main Resonator
Frequency 87Hz
Aux Resonator Frequency 450Hz
Material Plastic
Intake Manifold 3
Volume 1732 cm (1.8 qts)
rev 02
1.0L Engine: Exhaust 1-43
M-Car:
Engine Repair
Instructor Guide
ER-26
1. Pup–up Catalytic Converter

2. Front Exhaust Pipe/Catalytic Converter Assembly
3. Front Muffler Pipe
4. Rear Muffler Pipe

Type 3-way Catalyst
Front Catalyst
Volume 0.34 L (12 oz)
Type 3-way Catalyst
Main Catalyst
Volume 1.54 L (52 oz)
Front Muffler Volume 3.4 L (3.6 qts)
Rear Muffler Volume 9.0 L (9.5 qts)
rev 02
1-44 1.0L Engine: Cooling System Overview
M-Car:
Engine Repair
Instructor Guide
ER-27
1.0 L SOHC
Speed Application
ON OFF
ECT 93 90
Low
ECT sensor Malfunction
ECT 100 97
High
A/C COMP. ON
rev 02
1.0L Engine: Cooling System Overview 1-45
M-Car:
Engine Repair
Instructor Guide
Thermostat Cooling Fan
Cooling fan size 300 mm, 14 A
70~90.@23.
Coolin fan resistance
95~125.@125.
ER-28
* Open
- start to open : 82 dec ± 1.5
Thermostat operation
- Full open : 95 dec
* Close 80 dec
Radiator size (mm)

458 x 295 x 27
(Width x Height x Thickness)
rev 02
1-46 1.0L Engine: Fuel pump
M-Car:
Engine Repair The fuel pump is installed inside the fuel tank.
Instructor Guide If there is no reference pulse in ignition ON

state or the engine stops running, the ECM
will turn OFF the fuel pump 2 seconds later.
Fuel
The fuel pump delivers fuel to the fuel rail and
Pressure
injectors. The fuel system pressure is
Regulator
regulated by the fuel pressure regulator
located on the fuel pump assembly inside the
fuel tank.
The fuel pump contains the relief valve and the
check valve for safety.
Fuel Quantity Gage angle(¢ ª Resistance(k:) Remark

Full Stop 36.5 L / 38.5 qt 89 34.1
3/4 27.3 L / 28.8 qt 65 71.1
ER-29 1/2 18.4 L / 19.4 qt 45 114
1/4 9.14 L / 9.7 qt 15 201
Low 6.5 L / 6.9 qt 6 238 Warning lamp ON
Empty Stop 3.0 L 3.2 qt 0 299
Fuel Pressure regulator
a : Fuel Pressure Regulator b : Spring

c : Overflow Valve d : Diaphragm
* Fuel Pressure : 3.88 kg/cm2 or 55psi
* Fuel filter maintenance : Every 3 years or 45,000 km (installed on the fuel
rev 02
tank)
Evaporative Emission Canister 1-47
M-Car:
Engine Repair
The evaporative emission canister is an emission control device containing
activated charcoal granules. The evaporative emission canister is used to
store fuel vapors from the fuel tank. Instructor Guide
Once certain conditions are met, the electronic control module (ECM)
activates the controlled canister purge solenoid allowing the fuel vapors to be
drawn into the engine cylinders and burned.
* Capacity
• 0.8 SOHC : 900cc / 30 oz
• 1.0 SOHC : 1000cc / 34 oz
* Carbon Element : Activated Carbon
ER-30
Canister
CCCP Solenoid
rev 02
CAPÍTULO 2.1
MOTOR SIRIUS D3
Motor y Módulo de Control de Encendido (ECM) 800cc y 1000cc........... 5

Motor: Ubicación de componentes............................................................ 6
Motor: Entradas y salidas de ECM............................................................ 7
Motor: Sensor de oxígeno ó sensor lamda............................................... 8
Motor: Sensor de temperatura del refrigerante del motor (ECT)..............12
Motor: Sensor de temperatura de aire de entrada (IAT).......................... 14
Motor: Sensor de posición de aceleración (TPS)..................................... 15
Motor: Sensor de velocidad del vehículo (VSS)....................................... 17
Motor: Sensor de presión (MAP).............................................................. 19
Motor: Sensor de posición del cigueñal (CKP)......................................... 20
Motor: Sensor de posición del árbol de levas (CMP)............................... 21
Motor: Sensor de golpeteo....................................................................... 22
Motor: Termistor del evaporador de Aire acondicionado......................... 23
Motor: Interruptor de presión de dirección asistida.................................. 25
Motor: Detección de camino irregular...................................................... 26
Motor: Inyector de combustible................................................................ 28
Motor: Sistema de inyección electrónica (EI).......................................... 30
Motor: Recirculación de gases de escape (EEGR)................................. 32
Motor: Válvula IAC.................................................................................. .34
Motor: Solenoide de purga del cánister de carbón (CCCP)..................... 37
Motor: Módulo de control de encendido (ECM): diagnóstico................... 39
Motor: Códigos de falla por escaneado (DTC's):diagnóstico................... 40
Table of Contents 2.1-3
M-Car:
Engine
Engine and ECM Type: 0.8 and 1.0L ......................................................... 5 Performance
Engine: Components Location .................................................................. 6 Sirius-D3
Engine: ECM Input and Output .................................................................. 7 Instructor Guide
Engine: Oxygen Sensor ............................................................................. 8
Engine: Upstream Oxygen Sensor ............................................................ 9
Engine: Post Oxygen Sensor ................................................................... 11
Engine: Engine Coolant Temperature Sensor (ECT) ............................... 12
Engine: Intake Air Temperature Sensor ................................................... 14
Engine: Throttle Position Sensor (TPS) ................................................... 15
Engine: Vehicle Speed Sensor (VSS for A/T) .......................................... 17
Engine: Manifold Absolute Pressure Sensor ........................................... 19
Engine: Crankshaft Position Sensor (CKP) ............................................. 20
Engine: Camshaft Position Sensor (CMP) ............................................... 21
Engine: Knock Sensor ............................................................................. 22
Engine: Air Conditioning Evaporator Thermistor ..................................... 23
Engine: Power Steering Pressure Switch ................................................ 25
Engine: Rough Road Detection ............................................................... 26
Engine: Fuel Injector................................................................................ 28
Engine: EI System ................................................................................... 30
Engine: Electronic Exhaust Gas Recirculation (EEGR) ........................... 32
Engine: Idle Air Control (IAC) Valve ......................................................... 34
Engine: Controlled Charcoal Canister Purge (CCCP) Solenoid ............. 37
ECM and Diagnosis: Engine Control Module (ECM) ............................... 39 EP-1
ECM and Diagnosis: DTC’s .................................................................... 40
rev 02
2.1-4
M-Car:
Engine
Performance
Sirius-D3
Instructor Guide
rev 02
Engine and ECM Type: 0.8 and 1.0L 2.1-5
M-Car:
Engine
Engine Performance
Engine ECM Source Emission
Area Sirius-D3
Instructor Guide
Unleaded/Lead
0.8 L SOHC FENIX 5MR SASCO
ed
General
Unleaded/Lead
1.0 L SOHC SIRIUS D4 SIEMENS
ed
0.8 L SOHC SIRIUS D3 SIEMENS Euro Stage III

Western
Europe

Mexico
1. FENIX 5MR : SASCO (SIEMENS family) , 55 pins

2. SIRIUS D3/D4 : SIEMENS , 90 pins
rev 02
2.1-6 Engine: Components Location
M-Car:
Engine
Performance
Sirius-D3
Instructor Guide
To ECM
1. Manifold Air Temperature 6. Knock Sensor

Sensor (IAT) 7. Generator B+
2. Optical Sensor (Engine Speed 8. G103 Ground Point
Sensor)
9. Reverse Lamp Switch
3. Idle Air Control Valve (IAC)
10. O2 Sensor (only unleaded)
4. Throttle Position Sensor (TP
Sensor) 11. Cooland Temperature Sensor
(ECT)
rev 02 Soleniod (EGR)
Engine: ECM Input and Output 2.1-7
M-Car:
Engine
Input Control Output Performance
Sirius-D3
Instructor Guide
1. Power Supply (B+)

2. IG Power
3. MAP
4. TPS
1. Injector (Seguential)
5. ECT
2. SparkTiming
6. O2 Sensor (Pre&Post)
3. IACV
7. IAT
4. A/C COMP. Clutch Relay
8. Evaporator Thermistor
5. Fuel Pump Relay
9. VSS (M/T)
6. MIL
10. CKP Sensor
7. Cooling Fan (HI, LOW)
11. CMP Sensor
8. Canister Purge Solenoid
12. Knock Senor
9. EGR Solenoid
13. EEGR Position
10. Main Relay
14. Power Steering Oil
11. O2 sensor Heater
Pressure
12. Fuel Gage (PWM)
15. Headlamp ON Signal
13. Serial Gage (DLC)
16. A/C request Signal
17. Octane Select EP-2
18. Fuel Level Sensor
19. VR Sensor (W/O ABS)
20. Rough RD BWS (W/ABS)
21. Diagnostic Request
22. Ground
rev 02
2.1-8 Engine: Oxygen Sensor
M-Car:
Engine
Performance
General Operation
Sirius-D3 The Oxygen sensor is used to adjust and maintain preferred engine air/fuel
Instructor Guide mixtures to better control exhaust emissions and fuel economy.
Most automotive Oxygen sensors are made of Zirconium. This ceramic
material will produce a voltage in response to the amount of unused oxygen
in the exhaust stream. It does this by comparing the amount of oxygen in the
exhaust to the amount of oxygen in the air. When the exhaust is lean
(excess air), the sensor produces a low voltage (near zero volts). When the
exhaust is rich (excess fuel), it produces a high voltage (up to one volt).
For the sensor to work correctly, it needs a good source of outside air for
reference and a source of exhaust temperatures of at least 260 degrees C
(500 degrees F).
Typically, an unheated sensor is open to the atmosphere at the outer shield
and is heated by the exhaust gas. The ECM compares the voltage from the
oxygen sensor to the values programmed into it. If the air/fuel ratio is lean, it
adds fuel; and if the air/fuel ratio is rich, it reduce fuel to keep the engine
running properly.
The ECM uses Oxygen Sensor information for:
• Open loop/closed loop criteria
EP-3 • Ideal air/fuel ratio
Oxygen Sensor Element
21% Oxygen 21% Oxygen
0.6V 0.3V
0% 2%
Oxygen Oxygen
More Voltage Less Voltage

Output Output
Different Oxygen Levels
rev 02
Engine: Upstream Oxygen Sensor 2.1-9
M-Car:
Engine
Location Performance
Left side of the exhaust manifold Sirius-D3
Instructor Guide
Inspection
1. Connect the sensor, turn the ignition on and measure the voltage on the
signal line. If the reference value is not present, inspect for open or short
circuit.
Reference Value 400 – 500mV
2. After warming up the engine, measure the signal voltage during engine
idle. It should cycle below 300 mV and above 600 mV.
Reference Value Below 300 - Above 600mV

EP-4
If the measured value is not within the reference values, the cause may
be in the wiring, O2 sensor, ECM, or the engine.
ECM
77 LOW
2 1
13 HI
Exhaust Gas
rev 02
2.1-10 Engine: Upstream Oxygen Sensor
M-Car:
Engine
3. Lean fuel mixture signals: If the short term fuel mixture is near 0% or the
Performance
oxygen sensor signal voltage is changing under 300 mV, the cause may
Sirius-D3
be a:
Instructor Guide
• Faulty oxygen sensor
• Low fuel pressure
• Vacuum leak
• Faulty MAP sensor
• Clogged injector or fuel filter
• Faulty fuel pressure regulator
4. Rich fuel mixture signals: If the short term fuel trim is lower than 0% or
the oxygen sensor signal voltage is changing above 600 mV, the cause
may be a:
• Faulty oxygen sensor or ground
• Clogged fuel return line or air cleaner
• Faulty fuel pressure regulator or injector
• Faulty EGR valve or CCCP solenoid
• Faulty ignition system or engine timing
rev 02
Engine: Post Oxygen Sensor 2.1-11
M-Car:
Engine
General Operation Performance
Heaters are used to make O2sensors reach operating temperature faster than Sirius-D3
conventional unheated O2 sensors that are warmed by exhaust gas only. Instructor Guide
Location
Between the downstream catalytic converter and the front muffler
Inspection
EP-5
Main relay
“87”
(Heater Power) Heater Ground) Heated O2 Sensor
1. Heater temperature is maintained around 500° F (260° C) without ground

cycling because the internal resistance of the heater goes up and in turn
current across the heater decreases as the temperature rises.
• Resistance: 6W (pin: 1-2)
• Power supply: 12V at IGN ON (pin 2-ground)
• Ground supply: 0V at IGN ON (pin 4-ground)
2. O2 sensor signal
• Reference voltage at Ignition On: 400~500mV (connected)
• Reference signal in closed loop: remains around 450mV
rev 02
2.1-12 Engine: Engine Coolant Temperature Sensor (ECT)
M-Car:
Engine General Operation
Performance
Sirius-D3
The ETC Sensor is of the NTC type. Terminal
Instructor Guide
Bolt
NTC
Location
The ETC sensor is located on the front side of the engine block
EP-6
Inspection
ECM
5V
45
A ref
Signal
B 15
EVAP TEMP
rev 02
Engine: Engine Coolant Temperature Sensor (ECT) 2.1-13
M-Car:
Engine
1. IGN ON, disconnect the sensor connector and measure the voltage from Performance
the ECM at the connector terminal. Sirius-D3
• Reference value : 4.8 ~ 5.2 V Instructor Guide
If the above value is not measured, the sensor wiring is opened or

shorted or the ECM is malfunctioned.
2. Connect the sensor connector and measure the voltage at the signal
terminal according to engine temperature. (Thermostat should be in
normal condition)
• Reference value at normal operating temperature : 0.2 ~ 0.5 V
3. Disconnect the sensor connector and measure the resistance of the
sensor.
ECT Resistance
15 ± 0.25 4.1 ~ 4.7 K

20 3~4K
80 332
128 ± 0.25 77.7 ~ 84
rev 02
2.1-14 Engine: Intake Air Temperature Sensor
M-Car:
Engine
Performance Description
Sirius-D3 • Sensor Type: Negative Temperature Coefficient
Instructor Guide • Location : Air Cleaner
Inspection ECM
47 5V ref
2
Signal
IAT
EP-8
1
79
1. IGN ON, disconnect the sensor and measure the voltage from the ECM
between any two terminals of the connector.
Reference Value 4.8 – 5.2 V
If the above value is not present, the sensor wiring may be open or
shorted or the ECM has malfunctioned.
2. Connect the sensor and turn on the ignition and measure the voltage
between the ECM signal terminal and ground according to ambient
temperature.
3. Disconnect the sensor and measure the sensor resistance according to
temperature.
Temp. (°F) 14 23 32 41 59 68 77 86 95
Temp. (°C) -10 -5 0 5 15 20 25 30 35
Resistance (k 16,16 12,29 9,43 7,28 4,45 3,52 2,8 2,24 1,8
rev 02 Voltage (V) 4,58 4,46 4,31 4,15 3,74 3,5 3,25 2,99 2,73
Engine: Throttle Position Sensor (TPS) 2.1-15
M-Car:
Engine
The TPS is a three-wire variable resistor (potentiometer) mounted on the Sirius-D3
throttle body and operated by the throttle valve shaft. When the throttle valve Instructor Guide
is closed, the ECM reads a low voltage signal. When the throttle is wide open,
the ECM reads a high voltage signal. The voltage signal changes according to
the throttle position, about 0.5 volts at idle and about 4.5 volts at wide open
throttle (WOT).
The TPS signal is one of the parameters used by the ECM to calculate:
• Fuel Delivery
• Torque Converter Clutch (TCC) Application
• Transmission Shifting Schedule
• EVAP Control
• Ignition Ttiming
• EGR
• A/C
Location EP-9
rev 02
2.1-16 Engine: Throttle Position Sensor (TPS)
M-Car:
Engine
Performance
Inspection
Sirius-D3
Instructor Guide
1. IGN ON, disconnect the sensor, measure the voltage from the ECM
between terminal A and B of the connector.
EP-10
Reference Voltage 4.9 - 5.2 V
If the above value is not measured, the sensor wiring may be open or
2. IGN ON, connect the sensor, measure the signal voltage between
terminal C and ground according to the throttle valve position.
Throttle Position Signal Voltage

Idle 0.4 - 0.8 V
Wide Open 4.1 - 4.8 V
3. If the reference value is not measured, disconnect the sensor and

measure the resistance of each terminal.
Total Resistance (ter. A - B) 7Ω

Closed (ter. B - C) 2.6 Ω
W.O.T (ter. B - C) 8.3 Ω
rev 02
Engine: Vehicle Speed Sensor (VSS for A/T) 2.1-17
M-Car:
Engine
The VSS provides vehicle speed information to the ECM Sirius-D3
Instructor Guide
Signal ID Code
Ground “+” IG
Connector Terminal Vehicle Speed Sensor
Location
The VSS is located in the transaxle speedometer drive gear.
Inspection
EF4
EP-11
10A
2
1
21
rev 02
2.1-18 Engine: Vehicle Speed Sensor (VSS for A/T)
M-Car:
Engine
1. Disconnect the sensor, turn the ignition on and measure the voltage
Performance
between terminal 2 and 3.
Sirius-D3
Instructor Guide Reference Voltage 11-13 V
If the above value is not present, the fuse or the wiring may be open,
shorted, disconnected or a ground may be faulty.
2. Disconnect the sensor, measure the ECM voltage between terminal “1”
and “3” with the ignition on (Isolate the signal wire from other circuits).
Reference Voltage 12 V
If the reference value is not present, inspect the ECM and for open wiring.
3. Connect the sensor, turn the ignition key on and measure the signal
voltage between terminal “1” and ground to see if it changes while
turning the VSS shaft slowly.
Alternates between
Reference Voltage
1 and 12 V
(During driving between 6.81 and 8.48 V)
If the above value is not present the sensor is faulty.
rev 02
Engine: Manifold Absolute Pressure Sensor 2.1-19
M-Car:
Engine
Sirius-D3
Instructor Guide
The MAP sensor is of the piezo

resistivity type and is located on the
upper side of the dash panel.
The MAP sensor of Matiz II is different from the one of Matiz.

But Matiz II shares the same MAP for General area and Euro2000.
Inspection
A
EP-12
B Signal
1. Disconnect the sensor connector, turn the ignition key on and measure
the voltage between the terminal A and C of the connector to see Ref
voltage is supplied.
Reference voltage 4.5 ~ 5.2 V
If the above value is not measured, the sensor wiring is opened or the
ECM is malfunctioned. (check the connection with other sensors)
2. Connect the sensor connector, measure the voltage between terminal B
and ground with the ignition on. ( Isolate the signal wire from other
circuits)
Signal voltage 4.7 ~ 5.0 V
rev 02
2.1-20 Engine: Crankshaft Position Sensor (CKP)
M-Car:
Engine
Performance
General Operation
Sirius-D3 • Sensor Type: Inductive
Instructor Guide • Location: Rear end of crankshaft, target wheel is inside engine block
Inspection
EP-13
Shield Earth
High
Low
Item Value
1-2 460 - 620 (Ω)
Specification 2-3 > 1M (Ω)
1-3 > 1M (Ω)
Clearance (between CKP and Pulley) 0.3 - 1.7 mm (.001-.067 in)
Voltage (AC) 400 mV - 400 V
Tightening Torque 5 - 8 Nm (3.7 - 5.9 lb-ft)
rev 02
Engine: Camshaft Position Sensor (CMP) 2.1-21
M-Car:
Engine
Sensing #1 cylinder TDC Sirius-D3
• Sensor Type: Hall Effect sensor Instructor Guide
• Location: Cam sprocket
Inspection
Main Relay
CMP Sensor
7
EP-14
Signal
82
18
Terminal Ref. V
1 5V
3 12 V
2. Inspect the sensor
Clearance 0.3 - 2.0 mm

"1" - "2" ∞
Resistance
"2" - "3" ∞
rev 02
2.1-22 Engine: Knock Sensor
M-Car:
Engine
Performance
General Operation
Sirius-D3
Instructor Guide The knock sensor is of the piezo electric type and is located on the rear side
of the engine block.
Kock sensor location Knocking signal on acceleration
Inspection
Knock Sensor
Shield Earth
EP-15
50 Signal (+)
80 Signal (-)
19
Ter. 1 - 2
Resistance Ter. 1 - 3
Ter. 2 - 3
Sensitivity 18 ~ 34 mv/g (5 Khz)
Tightening torque 15 ~ 25 N.m
Note: Thanks to the knock sensor, a 3 ~ 5 % higher engine torque can be

achieved.
rev 02
Engine: Air Conditioning Evaporator Thermistor 2.1-23
M-Car:
Engine
When the evaporator temperature drops to 0° (32° F) or below, its core can Sirius-D3
frost or ice up, blocking air flow and in turn lowering cooling capacity. The Instructor Guide
thermistor senses evaporator temperature and prevents frost or ice build up
on the evaporator core surface. The ECM will cut off the compressor when
A/C Compressor Cut OFF

Item Condition
Engine Crank OFF OFF for 2.5 sec
Vehicle Start OFF OFF for 3 sec (RPM < 1500, TP > 5%)
OFF OFF for 5 sec ( 73!
Driving
ON 73ZLWKLQVHF
73 ! 966 N P
K
Sudden Accel
ON 9.4% < TP < 10% for 6 sec
Low Speed OFF OFF for 4 sec (TP > 30%, RPM < 1500)
Driving ON TP < 10%, RPM > 2000 for 4sec
A/C pressure OFF A/C pressure ¡ Â 2. 0 or ¡ Ã 32 kg/c
OFF Evap Temp ¡ Â 1
Evap Temp
ON Evap Temp > 2.45
OFF ECT ¡ Ã 115
ECT
ON ECT ¡ Â 112
EP-16
OFF RPM ¡ Â 640 or RPM ¡ Ã 66
RPM
ON 990 ¡ Â RPM ¡ Â 54
Location
The thermistor is located in the evaporator
Air Conditioning Evaporator Thermistor rev 02

2.1-24 Engine: Air Conditioning Evaporator Thermistor
M-Car:
Engine
Performance
Sirius-D3 Inspection
Instructor Guide
Evaporator
Temperature
Sensor
ECM
EVA SIG
C204 46
10 5V ref
15
16 Ground
Disconnect the sensor, turn the ignition key on and measure the voltage from
the ECM between terminal “1” and “2” of the connector.
EP-17 REF Voltage 4.8 - 5.2 V
If the above value is not measured, the sensor wiring is open, shorted, or the
ECM has malfunctioned.
rev 02
Engine: Power Steering Pressure Switch 2.1-25
M-Car:
Engine
When a driver turns the steering wheel, the engine RPM should increase Sirius-D3
compensating for engine power loss by increased power steering pressure. Instructor Guide
The ECM receives the power-steering-switch signal to calculate proper
engine RPM.
Location
EP-18
Power Steering Fluid Pressure Switch
Inspection
ECM
SIG
25
11 5V ref
C101
Powersteering Oil
Pressure Switch
(35 Bar)
(508 Psi)
rev 02
2.1-26 Engine: Rough Road Detection
M-Car:
Engine
Performance
General Operation
Sirius-D3 When the vehicle is travelling on a rough road, transmission oscillations could
Instructor Guide be recognized as engine misfires and the MIL will illuminate. In order to avoid
misfire detection in this case, a rough road sensor is included in the engine
management system.
The SIRIUS-D3 ECM uses the wheel speed sensor for rough road detection,
which is the same as the one used for the Lucas ABS system. The wheel
speed signal is transferred to the ECM as a analog signal.
Rough-Road
“Noise”
Rough-Road
Rough Road “Noise” Seen
as Misfire
Engine Speed
Wheel Speed (Flywhwwl Target)
(A.B.S. Sensor) Average
Engine
Speed
Time (S) Time (TDC)
EP-19
Config.
G Annalogical Signal Rough
Sensor to Filtering Road Rough Road
Logical Criterion
Detected
A.B.S. Event Signal Rough
Sensor Counter Processing Road
Criterion
Rough Road Detection and Misfire Detection
LH Front
Digital
Analog
VR Sensor
rev 02
Engine: Rough Road Detection 2.1-27
M-Car:
Engine
Inspection Performance
Sirius-D3
Instructor Guide
VR Sensor
NOTE: ABS Wheel Speed Sensor = VR Sensor
Appication Specification Remarks
0.4 - 1.0 mm
Air Gap
(.016 - .039 in)
at 20
Resistance 1.0 - 1.5 kΩ
(68 °F)
EP-20
Insulation Resistance ∞Ω
Turn wheel slowly by

AC voltage 0.1V hand (2.78 km/h)
(1.72mph)
rev 02
2.1-28 Engine: Fuel Injector
M-Car:
Engine
Performance Location
Sirius-D3
Instructor Guide
Injector Specification
Application
1.35 ± 4% (g/sec) or
Static Flow Rate
5.11 (L/sec)
Dynamic Flow Rate 2.565 ± 4% (g/sec) or
(WOT) 9.7 (L/sec)
Single hole,
EP-21 Spray Type
single spray
Injection Type Sequential
Resistance( 14.5 ± 5%
Fuel Cut-off: 6750 RPM (Immediate) / 6495 (Re-wetting)
rev 02
Engine: Fuel Injector 2.1-29
M-Car:
Engine
Sirius-D3
Instructor Guide
Main relay “1”
Injector
90 58 89
1. Disconnect the injector, turn the ignition on and measure the voltage of
the power supply terminals to see if battery voltage is present. If battery
voltage is not present, the engine compartment fuse or the wiring is
open.
2. Disconnect the injector, install a test lamp or a voltage meter on both
terminals of the connector and crank the engine. If the measured voltage
does not change or the test lamp stays on, the wiring between the
injector and the ECM is shorted to ground. If the test lamp stays off, the
wiring between the ECM terminal and the respective injector is open or
the ECM has malfunctioned.
3. Connect the injector, turn the ignition on and measure the voltage of
ECM terminals. If the voltage is not measured, the injector coil or the
wiring is open or disconnected.
Reference Value 11 - 13 V
4. Measure the resistance of the injector
Reference Value 14.5 Ω
rev 02
2.1-30 Engine: EI System
M-Car:
Engine
Performance
General Operation
Sirius-D3 SIRIUS-D3 ECM uses an EI (Electronic Ignition) system similar to the DIS or
Instructor Guide HEI system. The EI has its coil driver inside the ECM so that it is more
compact and reliable.
After the CKP (crankshaft position) and RPM signals are transferred to the
ECM, the coil driver controls the primary coils to generate high voltage at the
secondary side of the coils.
Location
EP-22
Inspection
1. Disconnect the EI module connector, turn the ignition on and measure
the voltage between the terminal “1” and ground. If battery voltage is not
measured the main relay or the wiring is opened or shorted or the
connector is bad connected.
2. Measure the coil resistance
Application Value
Primary coil 1.2 ± 0.2
Secondary coil 12.1 k
*Resistance of high tension cable (is changed due to EI system)
Reference value
Reference value 1.8 ~ 8 k
rev 02
Engine: EI System 2.1-31
M-Car:
Engine
Performance
Main Relay “87” Sirius-D3
Instructor Guide
EP-23
rev 02
2.1-32 Engine: Electronic Exhaust Gas Recirculation (EEGR)
M-Car:
Engine
Performance
Sirius-D3 General Operation
Instructor Guide The exhaust gas re-circulation control system includes an Electronic EGR
valve. It is a solenoid valve powered by the battery voltage through the main
relay. The EGR is controlled by PWM signals from the ECM.
Parameter Enable Condition
VSS ≥ 3 KPH (2 mph)
RPM < 4768
TPS Not closed/WOT
ECT ≥ 40
IAT ≥ 20
Battery Voltage ≥ 11.5 V
28 kpa (4/1 psi) <
MAP MAP
< 82.2 kpa (11.9 psi)
Air Fuel Ratio ≥ 13.4
Location
EP-24
EEGR Valve
Specifications
Application Values
Resistance 8 ± 0.5
Voltage 8 -16 V
Max. Coil Temp. 180
Operating Gas Temp. Max 450

Temp. Ambient Temp. -30 - 135
rev 02
Engine: Electronic Exhaust Gas Recirculation (EEGR) 2.1-33
M-Car:
Engine
Performance
Inspection Sirius-D3
Instructor Guide
Main Relay “87”
6 43 83 18
5V ref Signal
EP-25
Potentiometer Resistance
• Total Resistance (1-2): 3.2 kW + 30% / -10%
• Close (2-3): 0.91 kW
• Full Open (2-3): 2.95 kW
rev 02
2.1-34 Engine: Idle Air Control (IAC) Valve
M-Car:
Engine
Performance IAC
Sirius-D3
Instructor Guide ECM Pintle
Throttle Valve
Intake
Air
Throttle
Body
General Operation
The IAC valve is located in the throttle body. It has a movable pintle at one
end, driven by a small electric stepper motor, which is capable of moving in
exact, measured amounts called steps.
The ECM uses the IAC valve to control idle rpm. It performs this function by
changing the pintle position in the idle air passage of the throttle body. This
varies the airflow around the throttle plate when the throttle is closed.
During closed throttle, the ECM continuously compares actual idle rpm with
the programmed idle rpm and adjusts the IAC valve accordingly to achieve
the desired idle rpm. In some applications, the ECM also adjusts ignition
timing to control idle speed even more precisely.
To determine the desired position of the IAC pintle during idle or deceleration,
which is indicated by closed throttle position (0% throttle angle), the ECM
refers to the following inputs:
• Battery Voltage
• ECT
• TPS
• Engine Load (MAP, A/C compressor)
• Engine rpm
• Vehicle Speed
rev 02
Engine: Idle Air Control (IAC) Valve 2.1-35
M-Car:
Terminal
Engine
Pintle Step RPM
Cycle 1 2 3 4 Performance
Max open 204 Increase Sirius-D3
1 + - + -
Max close 0 Decrease
2 + - - +
Instructor Guide
3 - + - +
4 - + + -
5 + - + -
6 + - - +
Circuit and Inspection
HI
LOW
HI
LOW
1. Measure the voltage between IAC connector pins A through D and

ground while revving the engine. If the voltage is not present, the wiring
between the step motor and the ECM is open.
Terminals Voltage
A ↔ Ground
B ↔ Ground
Cycles 0.5V and 12V
C ↔ Ground
D ↔ Ground
2. Turn the ignition switch off, disconnect the IAC and then measure the
resistance of IAC valve.
Terminals Resistance
A↔ B 40 - 80 Ω
C↔D 40 - 80 Ω
A,B,C,D ↔ Ground ∞Ω
3. If the valves are found to be outside specifications, replace the valve. rev 02
M-Car:
Engine
Performance Resetting IAC Valve
Sirius-D3 1: Resetting IAC valve is needed when:
Instructor Guide
• Battery replacement
• ECM replacement
• IAC replacement
• Fault code clearing
2: Malfunction of IAC valve may induce:

• Poor Start
• Unstable Idle rpm
• A/C compressor clutch may be disengaged (A/C “ON”)
3: IAC Valve Resetting procedure with using IG key

1. IG switch OFF and disconnect battery “-” terminal for over 10
seconds
2. IG switch “ON” for 3~5 seconds
3. IG switch “OFF” for 3~5 seconds
4. IG switch is “ON” and cranking (ENG running)
5. Cycle the A/C switch and move shift lever several times.
Notice : Do not attempt to pull or push on the pintle of the IAC valve
that has been in service.
rev 02
Engine: Controlled Charcoal Canister Purge (CCCP) 2.1-37
Solenoid M-Car:
Engine
Performance
General Operation Sirius-D3
The basic evaporative emission (EVAP) control uses a charcoal canister Instructor Guide
storage method. This method transfers fuel vapor from the fuel tank to an
activated carbon (charcoal) storage canister that holds the vapors while the
vehicle is not operating. When the engine is running, the fuel vapor is purged
from the carbon element by intake airflow and consumed in the normal
combustion process.
Fuel vapor from the fuel tank flows through tubes into the canister. These
vapors are absorbed into the carbon. The ECM then purges the canister
when the engine has been running for a specific amount of time. Air is drawn
into the canister and mixes with the vapor. This mixture is then drawn into
the intake manifold.
The ECM commands the controlled canister purge solenoid valve. This valve
is ON or OFF controlled.
Poor idle, stalling, and poor drive-ability can be caused by the following:
• Inoperative CCCP valve
• Damaged canister
• Split hoses, cracked tubes, or improper connections
EP-26
Operation: ON/OFF
Parameter Enable Condition Disable Condition

Fuel Control Mode Closed Loop Open Loop
ECT > 40 °C or 104°F < 35 °C or 95°F
TP >0% WOT
Vehicle Speed > 0 km/h (0 mph)
Engine Not decel
Battery 8 V - 19 V
Vehicle 0.8 L
3
ON Min 30 L / min (1.1 ft /min)
Vent Flow Rate
3
OFF Below 0.05L / min (.02 ft /min)
Resistance 30 - 60 Ω
rev 02
2.1-38 Engine: Controlled Charcoal Canister Purge (CCCP)
M-Car: Solenoid
Engine
Performance
Sirius-D3 Location
Instructor Guide
Inspection
ECM
66 B +
Main Relay “87”
4
Canister Purge Solenoid
1. Disconnect the CCCP solenoid, turn the ignition on and measure the
voltage between the power supply terminal and ground. If battery voltage
is not present, check the relay operation for open wiring.
2. Measure the solenoid coil resistance:
Resistance (25° C / 77°F) 30 - 60 Ω
rev 02
ECM and Diagnosis: Engine Control Module (ECM) 2.1-39
M-Car:
Engine
ECM Type Performance
Sirius-D3
Model Maker Part No. Remark Option Instructor Guide
96291050 Non ABS

SIRIUS D3 SIEMENS 90 pins
96291049 ABS
Connector for Octane Value
Octane Value 95 91
Terminal 49 Ground Open
Location
The ECM is located under the dash on the driver’s side of the passenger
compartment. There are no serviceable parts in the ECM. The calibration data
is stored in a PROM.
rev 02
2.1-40 ECM and Diagnosis: DTCs
M-Car:
Engine DTC Function Type MIL
Performance P0107 Manifold Absolute Pressure Sensor Low Voltage A YES
Sirius-D3 Manifold Absolute Pressure Sensor High
P0108 A YES
Instructor Guide Voltage
P0112 Intake Air Temperature Sensor Low Voltage E YES
P0113 Intake Air Temperature Sensor High Voltage E YES
Engine Coolant Temperature Sensor Low
P0117 A YES
Voltage
Engine Coolant Temperature Sensor High
P0118 A YES
Voltage
P0122 Throttle Position Sensor Low Voltage A YES
P0123 Throttle Position Sensor High Voltage A YES
P0131 Oxygen Sensor Low Voltage A YES
P0132 Oxygen Sensor High Voltage A YES
P0133 Oxygen Sensor No Activity E YES
P0137 Heated Oxygen Sensor Low Voltage E YES
P0138 Heated Oxygen Sensor High Voltage E YES
P0140 Heated Oxygen Sensor No Activity E YES
P0141 Heated Oxygen Sensor Heater Malfuction E YES
P0171 Fuel Trim System Too Lean E YES
P0172 Fuel Trim System Too Rich E YES
P1230 Fuel Pump Relay Low Voltage A YES
P1231 Fuel Pump Relay High Voltage A YES
P0261 Injector 1 Low Voltage A YES
P0262 Injector 1 High Voltage A YES
P0300 Multiple Cylinder Misfire A/E YES
P1320 Crankshaft Segment Period Adaptation at Limit E YES
P1321 Crankshaft Segment Period Tooth Error E YES
P0327 Knock Sensor Circuit Fault E YES
Magnetic Crankshaft Position Sensor Electrical
P0335 E YES
Error
58X Crankshaft Position Sensor Extra/Missing
P0336 E YES
Pulse
P0337 58X Crankshaft Sensor No Signal E YES
P0341 Camshaft Position Sensor Rationality E YES
P0342 Camshaft Position Sensor No Signal E YES
P0351 Ignition Control Circuit A Fault A YES
P0352 Ignition Control Circuit B Fault A YES
P0353 Ignition Control Circuit C Fault A YES
P1382 Rough Road Data Invalid (Non ABS) D
rev 02 P1382 Rough Road Data Invalid (ABS) D
ECM and Diagnosis: DTCs 2.1-41
M-Car:
Engine
DTC Function Type MIL
Performance
P1385 Rough Road Sensor Circuit Fault (Non ABS) D Sirius-D3
P1385 Rough Road Sensor Circuit Fault (ABS) D Instructor Guide
P0400 Exhaust Gas Recirculation flow out of limit E YES
P1402 Exhaust Gas Recirculation Blocked E YES
P1403 Exhaust Gas Recirculation Valve Failure E YES
P0404 Exhaust Gas Recirculation (EGR) Opened E YES
P1404 Exhaust Gas Recirculation (EGR) Closed E YES
Exhaust Gas Recirculation Pintle Position
P0405 E YES
Sensor High Voltage
P0406 E YES
Sensor Low Voltage
P0420 Catalyst(Oxygen Sensor) Low Efficiency E YES
P0444 EVAP Purge Control Circuit No Signal E YES
P0445 EVAP Purge Control Circuit Fault E YES
P0462 Fuel Level Sensor Low Voltage D
P0463 Fuel Level Sensor High Voltage D
Low Speed Cooling Fan Relay Circuit Fault
P0480 D
(Without A/C)
Low Speed Cooling Fan Relay Circuit Fault
P0480 D
(With A/C)
High Speed Cooling Fan Relay High Voltage
P0481 D
(Without A/C)
High Speed Cooling Fan Relay High Voltage
P0481 D
(With A/C)
P0501 Vehicle Speed No Signal (M/T only) A YES
P0505 Idle Air Control Valve (IACV) Error E YES
P1535 Evaporator Temperature Sensor High Voltage D
P1536 Evaporator Temperature Sensor Low Voltage D
P1537 A/C Compressor Relay High Voltage D
P1538 A/C Compressor Relay Low Voltage D
P0562 System Voltage (Engine Side) Too Low D
P0563 System Voltage (Engine Side) Too High D
P0601 Engine Control Module Check-sum Error E YES
P0604 Engine Control Module RAM Error E YES
P0605 Engine Control Module Write Error E YES
P1610 Main Relay High Voltage A YES
P1611 Main Relay Low Voltage A YES
P1628 Immobilizer No Successful Communication D
P1629 Immobilizer Wrong Computation D
P0656 Fuel Level Gauge High Circuit Fault D
P1660 Malfunction Indicator Lamp(MIL) High Voltage B YES
P1661 Malfunction Indicator Lamp (MIL) Low Voltage B YES
rev 02
CAPÍTULO 2.2
MOTOR SIRIUS D4

Motor: Entradas y salidas de ECM............................................................ 6

Motor: Actuador de ralentí/sensor de posición de acelerador (MTIA)...... 13
Motor: Sensor de posición del cigueñal (CKP)......................................... 20
Motor: Sensor de posición del árbol de levas (CMP)............................... 21

Motor: Detección de camino irregular...................................................... 26
Motor: Sistema de inyección electrónica (EI).......................................... 30
Motor: Recirculación de gases de escape (EEGR)................................. 32

M-Car:
Engine
Engine and ECM Type: 0.8 and 1.0L ......................................................... 5 Performance
Engine: ECM Input and Output .................................................................. 6 Sirius-D4
Engine: Upstream Oxygen Sensor ............................................................ 7 Instructor Guide
Engine: Post Oxygen Sensor ..................................................................... 9
Engine: Intake Air Temperature Sensor ................................................... 12
Engine: Main Throttle Idle Actuator (MTIA) .............................................. 13
Engine: Vehicle Speed Sensor (VSS for A/T) .......................................... 16
Engine: Manifold Absolute Pressure Sensor ........................................... 18
Engine: Crankshaft Position Sensor (CKP) ............................................. 20
Engine: Camshaft Position Sensor (CMP) ............................................... 21
Engine: Rough Road Detection ............................................................... 26
Engine: EI System ................................................................................... 30
Engine: Electronic Exhaust Gas Recirculation (EEGR) ........................... 32
ECM and Diagnosis: Engine Control Module (ECM) ............................... 36
ECM and Diagnosis: DTC’s .................................................................... 37
EP-27
rev 02
2.2-4
M-Car:
Engine
Performance
Sirius-D4
Instructor Guide
rev 02
Engine and ECM Type: 0.8 and 1.0L 2.2-5
M-Car:
Engine
Engine Performance
Engine ECM Source Emission
Area Sirius-D4
Instructor Guide
Unleaded/Lead
0.8 L SOHC FENIX 5MR SASCO
ed
General
Unleaded/Lead
1.0 L SOHC SIRIUS D4 SIEMENS
ed

Western
Europe

Mexico

rev 02
2.2-6 Engine: ECM Input and Output
M-Car:
Engine
Performance Input Control Output
Sirius-D4
Instructor Guide

2. IG Power 1. Injector (Seguential)
3. MAP 2. SparkTiming
4. TPS 3. IACV
5. ECT 4. A/C COMP. Clutch Relay
6. O2 Sensor (Pre&Post) 5. Fuel Pump Relay
7. IAT 6. MIL
8. Evaporator Thermistor 7. Cooling Fan (HI, LOW)
9. VSS (M/T) 8. Canister Purge Solenoid
10. CKP Sensor 9. EGR Solenoid
11. CMP Sensor 10. Main Relay
12. Knock Senor 11. O2 sensor Heater
13. EEGR Position 12. Fuel Gage (PWM)
14. Power Steering Oil 13. Serial Gage (DLC)
Pressure
15. Headlamp ON Signal
16. A/C request Signal
EP-28 17. Octane Select
18. Fuel Level Sensor
19. VR Sensor (W/O ABS)
20. Rough RD BWS (W/ABS)
22. Ground
rev 02
Engine: Upstream Oxygen Sensor 2.2-7
M-Car:
General Operation Engine
Performance
A heater is adopted additionally to make O2S reach operating temperature Sirius-D4
earlier. Instructor Guide
The heater is PWM controlled by the ECM.
Type Zirconia
Heating type Heated
lean to rich 150 ms
Response time
rich to lean 250 ms
Heater resistance 6.0
A B Sensor Ground
Sensor Signal
EP-29
Heater Heater
C D
Location
Left side of the exhaust manifold
rev 02
M-Car:
Engine
Performance
Inspection
Sirius-D4
Instructor Guide
ECM
Main Relay Signal
35 44 13
A C B D
1. Heater
• Resistance : 6 Ohm (pin : A-C)
• Power : 12V at IGN ON (pin A-ground)
2. O2 sensor signal
• Reference voltage at Ignition ON : 400~500mV (connector
connected)
EP-30 • Reference signal in closed loop : Toggle 150 ~ 750 mV
3. The cause of lean signals :
• The faulty oxygen sensor
• Low fuel pressure
• Vacuum leak
• Clogged injector or fuel filter
• Faulty fuel pressure regulator
4. The cause of rich signals
• Faulty oxygen sensor or ground
• Clogged fuel return line or air cleaner
• Faulty fuel pressure regulator or injector
• Faulty EGR valve or CCCP solenoid
• Faulty ignition system or engine timing
rev 02
Engine: Post Oxygen Sensor 2.2-9
M-Car:
Engine
Sirius-D4
Type Zirconia Sensor 1 3 Sensor Instructor Guide
Signal Ground
Heating type Heated
lean to rich 150 ms Heater Heater
Response time Ground
rich to lean 250 ms 2 4
Heater resistance 6.0
Location
The Post Oxygen Sensor is located

just after the rear catalytic converter
EP-31
Inspection
ECM
Main Relay Signal
64 14 16
2 4 1 3
1. Heater
• Resistance : 6 Ohm (pin : 2-4)
• Power : 12V at IGN ON (pin 2-ground)
2. O2 sensor signal
• Reference voltage at Ignition ON : 400~500mV (connector
connected)
• Reference signal in closed loop : Toggle 150 ~ 750 mV very
slowly rev 02
M-Car:
Engine
Performance
Instructor Guide
Terminal
Bolt
NTC
EP-32
Location
Beside the thermostat
rev 02
M-Car:
Engine
Sirius-D4
Instructor Guide
ECM
76 5V ref
1
Signal
ECT
2
19
1. IGN ON, disconnect the sensor connector and measure the voltage
from the ECM at the connector terminal.
• Reference value : 4.8 ~ 5.2 V
If the above value is not measured, the sensor wiring is opened or
shorted or the ECM is malfunctioned.
2. Connect the sensor connector and measure the voltage at the signal
terminal according to engine temperature. (Thermostat should be in
normal condition)
• Reference value at normal operating temperature : 1.5 ~ 2.0 V
3. Disconnect the sensor connector and measure the resistance of the
sensor.
ECT Resistance
20 3520,0
50 185,2
80 332,0
85 49,2
105 27,5
rev 02
M-Car:
Engine
Performance General Operation
Sirius-D4 • Sensor Type: Negative Temperature Coefficient
Instructor Guide
Location
On the intale manifold
Inspection ECM
78 5V ref
1
SIgnal
IAT
EP-33
2
13
temperature.
temperature.
Temp. (°F) 14 23 32 41 59 68 77 86 95
Temp. (°C) -10 -5 0 5 15 20 25 30 35
Resistance (k 16,16 12,29 9,43 7,28 4,45 3,52 2,8 2,24 1,8
rev 02 Voltage (V) 4,58 4,46 4,31 4,15 3,74 3,5 3,25 2,99 2,73
Engine: Main Throttle Idle Actuator (MTIA) 2.2-13
M-Car:
Engine
The MTIA is a kind of throttle body of which the integrated motor adjusts the Sirius-D4
throttle flap angle directly to keep idle rpm properly substituting the Idle Air Instructor Guide
Control valve previously used.
The ECM controls the throttle actuator in order to adjust engine idle speed
with signals received from sensors.
The MTIA does not by-pass the air during idle but controls the throttle angle
directly by the DC motor, which is controlled according to the PWM signals
from the ECM to adjust needed air for the engine running. As a result, It
contributes in meeting newly reinforced exhaust gas regulations and coping
with reliability.
Besides the MTIA contains the idle switch and two potentiometers (the
throttle position sensor and the motor position sensor) to recognize accurate
idle range and throttle valve position so that the it supplies three signals to
the ECM all the time.
There is an emergency mode to secure the safety for drivers in which the
throttle angle is basically 5.1 % open to supply small amount of air for driving
in spite of the throttle body malfunction.
EP-35
Spring Idle Full load
F1
F2-A
F2-B
Plate
Accel. Pedel
Idle Emergency
Throttle
F4 Position
Idle Min Sensor
Idle Max.
Idle Switch
Motor
Position
Sensor
Motor
rev 02
2.2-14 Engine: Main Throttle Idle Actuator (MTIA)
M-Car:
Engine
Performance The MTIA controls the throttle angle between 0° and 24° by the motor.
Sirius-D4 Above Idle speed, the throttle angle is controlled mechanically by the cable.
Instructor Guide
APPLICATION Specification Remarks
Bore size PP
Limp home position 5.1 Emergency mode

EP-36 Air flow 41 ~ 50.5 kg/h Idle maximum air flow
Air leakage 1.5 ~ 3.5 kg/h Idle minimum air flow
Inspection
PIN Description
1 Motor (+)
2 Motor (-)
1 3 5 7
3 Idle switch
2 4 6 8 4 MTIA 5V ref
5 Throttle position
6 -
7 Ground
8 Motor position
rev 02
Engine: Main Throttle Idle Actuator (MTIA) 2.2-15
M-Car:
Engine
Performance
Sirius-D4
Instructor Guide
IDLE S/W
Signal
Motor position
5V Ref
Throttle position
1. Disconnect the MTIA connector, turn the ignition on and measure

the voltage. EP-37
MTIA connector No. Reference value
3↔7 12 V
4↔7 5V
2. If the reference value is not measured, inspect the sensor wiring

open or short or the ECM. And measure the signal voltage
Throttle position signal

Throttle opening
(ECM "74" - "19")
Idle 4.15 ~ 4.75 V
Wide open throttle 1.05 ~ 0.30 V
If the reference value is not measured, replace the MTIA

3. Inspect the DC motor
DC motor resistance 4.0
rev 02
2.2-16 Engine: Vehicle Speed Sensor (VSS for A/T)
M-Car:
Engine
Performance
General Operation
Sirius-D4 The VSS provides vehicle speed information to the ECM.
Instructor Guide
Signal ID Code
Ground “+” IG
Connector Terminal Vehicle Speed Sensor
Location
The VSS is located in the transaxle speedometer drive gear.
Inspection
EP-38
IGN 1
10A
ECM
1 Signal
51 12V ref
VSS (M/T) 2
G104
rev 02
Engine: Vehicle Speed Sensor (VSS for A/T) 2.2-17
M-Car:
Engine
Performance
between terminal 2 and 3.
Sirius-D4
Reference Voltage 11-13 V Instructor Guide
If the above value is not present, the fuse or the wiring may be open,
shorted, disconnected or a ground may be faulty.
2. Disconnect the sensor, measure the ECM voltage between terminal “1”
and “3” with the ignition on (Isolate the signal wire from other circuits).
Reference Voltage 12 V
If the reference value is not present, inspect the ECM and for open wiring.
3. Connect the sensor, turn the ignition key on and measure the signal
voltage between terminal “1” and ground to see if it changes while
turning the VSS shaft slowly.
Alternates between
Reference Voltage
1 and 12 V
(During driving between 6.81 and 8.48 V)
If the above value is not present the sensor is faulty.
rev 02
2.2-18 Engine: Manifold Absolute Pressure Sensor
M-Car:
Engine
Performance
General Operation
Sirius-D4
Instructor Guide
Ground
Vref
Signal
Location
The piezo type sensor is located on the intake manifold.
EP-39
rev 02
Engine: Manifold Absolute Pressure Sensor 2.2-19
M-Car:
Engine
Sirius-D4
MAP Instructor Guide
A 50 5V Ref
B 75 Signal
C 13
1. Disconnect the sensor connector, turn the ignition key on and measure
the voltage between the terminal A and C of the connector to see Ref
voltage is supplied.
Reference voltage 4.5 ~ 5.5 V
If the above value is not measured, the sensor wiring is opened or the
ECM is malfunctioned. (check the connection with other sensors)
2. Connect the sensor connector, measure the voltage between terminal B
and ground with the ignition on. ( Isolate the signal wire from other
circuits) EP-40
Signal voltage 4.7 ~ 5.0 V
3. Run and idle the engine and measure the signal voltage between terminal
“B” and ground. (Engine warmed-up above 80°C, No load)
Reference 1.0~1.5 V Idle

voltage 4.5 ~ 4.8 V WOT
4. Connect the sensor connector, turn the ignition key on and connect the
vacuum pump on the sensor vacuum terminal and measure the signal
voltage between terminal “B” and ground as vacuum changes.
Vacuum pump pressure Signal voltage Vacuum pump pressure Signal voltage
120 KPA 4.691 - 4.819 V 40 KPA 1.259 - 1.387 V
95 KPA 3.618 - 3.747 V 15 KPA 0.186 - 0.315 V
rev 02
2.2-20 Engine: Crankshaft Position Sensor (CKP)
M-Car:
Engine
Performance
General Operation
Sirius-D4 • Sensor Type: Inductive
Instructor Guide
Location
Rear end of crankshaft, target wheel is inside engine block
EP-41
Shield Earth
High
Low
Item Value
1-2 460 - 620 (W)
Specification 2-3 > 1M (W)
1-3 > 1M (W)
Clearance (between CKP and Pulley) 0.3 - 1.7 mm (.001-.067 in)
Voltage (AC) 400 mV - 400 V
Tightening Torque 5 - 8 Nm (3.7 - 5.9 lb-ft)
rev 02
Engine: Camshaft Position Sensor (CMP) 2.2-21
M-Car:
Engine
Sensing #1 cylinder TDC Sirius-D4
• Sensor Type: Hall Effect sensor Instructor Guide
Location
Beside the thermostat housing
Inspection
Main Relay
CMP Sensor
7
EP-42
Signal
22 5V Ref
17
2. Inspect the sensor
Application Terminals 1.0 SOHC

"1" - "2" 5V
Ref. V
"2" - "3" 12 V
"1" - "2"
Resistance
"2" - "3"
Clearance 0.3 ~ 2.0 mm
rev 02
M-Car:
Engine
Performance
General Operation
Sirius-D4
Instructor Guide The knock sensor is of the piezo electric type and is located on the rear side
of the engine block.
Kock sensor location Knocking signal on acceleration
Inspection
Knock Sensor
Shield Earth
EP-43 42 Signal (+)
12 Signal (-)
11
Ter. 1 - 2 ∞
Resistance Ter. 1 - 3 ∞
Ter. 2 - 3 ∞
Sensitivity 18 ~ 34 mv/g (5 Khz)

achieved.
rev 02
M-Car:
Engine
When the evaporator temperature drops to 0° (32° F) or below, its core can Sirius-D4

Item Condition
Driving
ON 73ZLWKLQVHF
73 ! 966 N P
K
Sudden Accel
ON 9.4% < TP < 10% for 6 sec
Evap Temp
ON Evap Temp > 2.45
OFF ECT ¡ Ã 115
ECT
ON ECT ¡ Â 112
OFF RPM ¡ Â 640 or RPM ¡ Ã 66 EP-44
RPM
ON 990 ¡ Â RPM ¡ Â 54
Location

M-Car:
Engine
Performance
Inspection
Sirius-D4
Instructor Guide Evaporator
Temperature
Sensor
ECM
EVA SIG
C204 46
10 5V ref
15
16 Ground
REF Voltage 4.8 - 5.2 V

EP-45
rev 02
M-Car:
Engine
When a driver turns the steering wheel, the engine RPM should increase Sirius-D4
engine RPM.

Pressure
Actuation Pressure EP-46

35 bar
Release Pressure
3.5 ~ 7.8 bar
OFF ON Switch Displacement
Inspection
ECM
Signal
83
11 C101
Power
Steering
Pressure
Switch
rev 02
2.2-26 Engine: Rough Road Detection
M-Car:
Engine
Performance
General Operation
Sirius-D4 When engine is running on a rough road, then transmission oscillations may
Instructor Guide be recognized as misfires and the MIL will switch up.
In order to avoid misfire detection in this case, a rough road sensor is
included in the engine management system.
The ABS controller sends rough road signals to the ECM.
The vehicles without ABS option uses the hall sensor for rough road
detection.
Rough-Road
“Noise”
Rough-Road
Rough Road “Noise” Seen
as Misfire
Engine Speed
Wheel Speed (Flywhwwl Target)
(A.B.S. Sensor) Average
Engine
Speed
EP-47 Time (S) Time (TDC)
Config.
G Annalogical Signal Rough
Sensor to Filtering Road Rough Road
Logical Criterion
Detected
A.B.S. Event Signal Rough
Sensor Counter Processing Road
Criterion
Rough Road Detection and Misfire Detection
LH Front
Digital
Analog
VR Sensor
rev 02
Engine: Rough Road Detection 2.2-27
M-Car:
Engine
Sirius-D4
Instructor Guide
A
Main Relay
ECM
EBCM
B 53 Sig
C 17 cpu
Ref
G Sensor
EP-48
rev 02
M-Car:
Engine
Performance Location
Sirius-D4
Instructor Guide
Injector Specification
Application
EP-49 Static Flow Rate
1.35 ± 4% (g/sec) or
5.11 (L/sec)
Dynamic Flow Rate 2.565 ± 4% (g/sec) or
(WOT) 9.7 (L/sec)
Single hole,
Spray Type
single spray
Fuel Cut-off:
• Cut-off : 6500 RPM
• Re-wetting : 6000 RPM
rev 02
M-Car:
Engine
Sirius-D4
Instructor Guide
Injectors
59 90 60 89
the power supply terminals to see if battery voltage is present. If battery
voltage is not present, the engine compartment fuse or the wiring is
open.
2. Disconnect the injector, install a test lamp or a voltage meter on both
terminals of the connector and crank the engine. If the measured voltage
does not change or the test lamp stays on, the wiring between the
injector and the ECM is shorted to ground. If the test lamp stays off, the
wiring between the ECM terminal and the respective injector is open or
the ECM has malfunctioned.
3. Connect the injector, turn the ignition on and measure the voltage of
ECM terminals. If the voltage is not measured, the injector coil or the
wiring is open or disconnected.
Reference Value 11 - 13 V
4. Measure the resistance of the injector
Reference Value 14.5 Ω
rev 02
2.2-30 Engine: EI System
M-Car:
Engine
Performance
General Operation
Sirius-D4 SIRIUS-D4 ECM uses the EI(Electronic Ignition) system. The EI has its coil
Instructor Guide driver inside the ECM so that it becomes more compact and reliable.
VB
Cyl 1 and 4 Cyl 2 and 3
EP-50
CBA
Inspection
1. Disconnect the EI module connector, turn the ignition on and measure
the voltage between the terminal “1” and ground. If battery voltage is not
measured the main relay or the wiring is opened or shorted or the
connector is bad connected.
2. Measure the coil resistance
Application Value
Primary coil 0.5 ± 0.05
Secondary coil 5.1 ± 0.3 k
*Resistance of high tension cable (is changed due to EI system)
Reference
Referencevalue
value 1.8 ~ 8 k
rev 02
Engine: EI System 2.2-31
M-Car:
Engine
cyl.1 cyl.4 cyl.2 cyl.3 Performance
Sirius-D4
Electronic
Instructor Guide
Ignition
(EI)
system
RED
/YEL RED/ DK
YEL RED BLU /
RED/YEL RED
RED
/YEL
DK DK BLU
RED BLU / /WHT
RED
Ignition
Feed
rev 02
2.2-32 Engine: Electronic Exhaust Gas Recirculation (EEGR)
M-Car:
Engine
Performance
Instructor Guide The exhaust gas re-circulation control system includes an Electronic EGR
valve. It is a solenoid valve powered by the battery voltage through the main
relay. The EGR is controlled by PWM signals from the ECM.
VSS ≥ 3 KPH (2 mph)
RPM < 4768
TPS Not closed/WOT
ECT ≥ 40
IAT ≥ 20
Battery Voltage ≥ 11.5 V
28 kpa (4/1 psi) < MAP
MAP
< 82.2 kpa (11.9 psi)
Air Fuel Ratio ≥ 13.4
Application Values
Resistance 8 ± 0.5
Voltage 8 -16 V
EP-51 Max. Coil Temp. 180

Operating Gas Temp. Max 450
Temp. Ambient Temp. -30 - 135
Location
5 Solenoid (EGR-PWM)
6 Sensor Signal
4 Sensor
Ground
1 Solenoid + (Vb) 2 Sensor

Supply - 5V
rev 02
Engine: Electronic Exhaust Gas Recirculation (EEGR) 2.2-33
M-Car:
Engine
Performance
Inspection Sirius-D4
Instructor Guide
Main Relay “87”
5 79 45 19
5V ref Signal
EP-52
Potentiometer Resistance
• Total Resistance (1-2): 3.2 kW + 30% / -10%
• Close (2-3): 0.91 kW
• Full Open (2-3): 2.95 kW
rev 02
M-Car: Solenoid
Engine
Performance
Instructor Guide The basic evaporative emission (EVAP) control uses a charcoal canister
combustion process.
Operation: ON/OFFThe CCCP is duty controlled

Vehicle 0.8 SOHC 1.0 SOHC
ON 33.3~43.3L / min (-200~700mmHg) 28~40 L / mim
Vent flow rate
OFF Below 0.033L / min 0.3L / min
Resistance 24 ~ 28 §Ù(25 22 ~ 28 §Ù(20
Frequency 10 Hz 10 Hz
Duty 0 ~100% 0 ~100%
rev 02
Solenoid M-Car:
Engine
Performance
Location Sirius-D4
Instructor Guide
Inspection
EP-53
ECM
66 B +
Main Relay “87”
65
Canister Purge Solenoid
Resistance (20 22 ~ 28
rev 02
2.2-36 ECM and Diagnosis: Engine Control Module (ECM)
M-Car:
Engine
Performance
Octane Connector
Sirius-D4
Instructor Guide Octane value 95 91
Terminal "27" Ground Open
Location
The ECM is located under the dash on the driver’s side of the passenger
compartment. There are no serviceable parts in the ECM. The calibration data
is stored in a EEPROM.
rev 02
ECM and Diagnosis: DTCs 2.2-37
M-Car:
Engine
Performance
P0107 Manifold Absolute Pressure Sensor Low Voltage A YES
Sirius-D4
Manifold Absolute Pressure Sensor High Instructor Guide
P0108 A YES
Voltage
P0112 Intake Air Temperature Sensor Low Voltage E YES
P0113 Intake Air Temperature Sensor High Voltage E YES
P0117 A YES
Voltage
P0118 A YES
Voltage
P0122 Throttle Position Sensor Low Voltage A YES
P0123 Throttle Position Sensor High Voltage A YES
P0131 Front Heated Oxygen Sensor Low Voltage A YES
P0132 Front Heated Oxygen Sensor High Voltage A YES
P0133 Front Heated Oxygen Sensor No Activity E YES
P0135 Front Heated Oxygen Sensor Heater Malfuction E YES
P0137 Rear Heated Oxygen Sensor Low Voltage E YES
P0138 Rear Heated Oxygen Sensor High Voltage E YES
P0140 Rear Heated Oxygen Sensor No Activity E YES
P0141 Rear Heated Oxygen Sensor Heater Malfuction E YES
P0171 Fuel Trim System Too Lean E YES
P0172 Fuel Trim System Too Rich E YES
P0222 MTIA Low Voltage A YES
P0223 MTIA High Voltage A YES
P1230 Fuel Pump Relay Low Voltage A YES
P1231 Fuel Pump Relay High Voltage A YES
P0300 Multiple Cylinder Misfire (Catalyst damage) A Blinking
P0300 Multiple Cylinder Misfire (Emission) E YES
P1320 Crankshaft Segment Period Adaptation at Limit E YES
P1321 Crankshaft Segment Period Tooth Error E YES
P0327 Knock Sensor Circuit Fault E YES
Magnetic Crankshaft Position Sensor Electrical
P0335 E YES
Error
58X Crankshaft Position Sensor Extra/Missing
P0336 E YES
Pulse
P0337 58X Crankshaft Sensor No Signal E YES
P0341 Camshaft Position Sensor Rationality E YES
P0342 Camshaft Position Sensor No Signal E YES rev 02
2.2-38 ECM and Diagnosis: DTCs
M-Car:
Engine
Performance
Sirius-D4 P0351 Ignition Control Circuit A Fault A YES
Instructor Guide P0352 Ignition Control Circuit B Fault A YES
P1382 Rough Road Data Invalid Cnl No
P1385 Rough Road Sensor Circuit Fault Cnl No
P0400 Exhaust Gas Recirculation flow out of limit E YES
P1402 Exhaust Gas Recirculation Blocked E YES
P1403 Exhaust Gas Recirculation Valve Failure E YES
P0404 Exhaust Gas Recirculation (EGR) Opened E YES
P1404 Exhaust Gas Recirculation (EGR) Closed E YES
P0405 E YES
Sensor High Voltage
P0406 E YES
Sensor High Voltage
P0420 Catalyst(Oxygen Sensor) Low Efficiency E YES
P0444 EVAP Purge Control Circuit No Signal E YES
P0445 EVAP Purge Control Circuit Fault E YES
P0462 Fuel Level Sensor Low Voltage Cnl No
P0463 Fuel Level Sensor High Voltage Cnl No
P0480 Low Speed Cooling Fan Relay Circuit Fault Cnl No
P0481 High Speed Cooling Fan Relay High Voltage Cnl No
P0501 Vehicle Speed No Signal (M/T only) A YES
P0510 Trottle Position Switch Circuit Fault A YES
P1511 Idle Charge Actuator Circuit Fault E YES
P1512 Idle Charge Actuator Mechanical Error E YES
P1513 Idle Charge Actuator Functional Error Cnl No
P1537 A/C Compressor Relay High Voltage Cnl No
P1538 A/C Compressor Relay Low Voltage Cnl No
P0562 System Voltage (Engine Side) Too Low Cnl No
P0563 System Voltage (Engine Side) Too High Cnl No
P0601 Engine Control Module Check-sum Error E YES
P0604 Engine Control Module RAM Error E YES
P0605 Engine Control Module Write Error E YES
P1610 Main Relay High Voltage A YES
P1611 Main Relay Low Voltage A YES
P1628 Immobilizer No Successful Communication Cnl No
P1629 Immobilizer Wrong Computation Cnl No
P0656 Fuel Level Gauge High Circuit Fault Cnl No
P1660 Malfunction Indicator Lamp(MIL) High Voltage E YES
P1661 Malfunction Indicator Lamp (MIL) Low Voltage E YES
rev 02
CAPÍTULO 2.3
MOTOR FENIX 5MR

Motor: Ubicación de componentes............................................................ 6
Motor: Diagrama de entradas y salidas de ECM....................................... 7
Motor: Entradas y salidas del ECM........................................................... 8

Motor: Sensor de posición de aceleración (TPS).................................... 15

Motor: Sistema de ignición por distribuidor.............................................. 29
Motor: Recirculación de gases de escape (EGR).................................... 32

Motor: Válvula IAC................................................................................... 34
Motor: Lámpara de atención pronta de motor (Check Engine)................ 40
M-Car:
Engine
Engine and ECM Type: 0.8L and 1.0L ...................................................... 5 Performance
Engine: Components Location .................................................................. 6 Fenix 5 MR
Engine: ECM Input & Output Schematic .................................................... 7 Instructor Guide
Engine: ECM Input and Output .................................................................. 8
Engine: Oxygen Sensor ............................................................................. 9
Engine: Upstream Oxygen Sensor .......................................................... 10
Engine: Intake Air Temperature Sensor (IAT) ........................................... 13
Engine: Throttle Position Sensor (TPS) ................................................... 15
Engine: Vehicle Speed Sensor (VSS, for M/T) ........................................ 17
Engine: Manifold Absolute Pressure Sensor (MAP) ................................ 19
Engine: Distributor Ignition System.......................................................... 29
Engine: Exhaust Gas Recirculation (EGR) .............................................. 32
Engine: Idle Air Control (IAC) Valve ......................................................... 34
ECM & Diagnosis: Engine Control Module ............................................. 39
ECM & Diagnosis: Service Engine Soon Lamp ....................................... 40
ECM & Diagnosis: DTC .......................................................................... 41
Engine Performance: Lab 1 ..................................................................... 42 EP-54
Engine Performance: Lab 2 ..................................................................... 43
Engine Performance: Test Questions ....................................................... 44
rev 02
2.3-4
M-Car:
Engine
Performance
Fenix 5 MR
Instructor Guide
rev 02
Engine and ECM Type: 0.8L and 1.0L 2.3-5
M-Car:
Engine
Engine Performance
Engine EC M Source Emission
Are a Fenix 5 MR
Unleaded/Lead
Instructor Guide
0.8 L SO HC FENIX 5MR SASC O
ed
General
Unleaded/Lead
1.0 L SO HC SIR IUS D 4 SIEMENS
ed
0.8 L SO HC SIR IUS D 3 SIEMENS Euro Stage III

W es tern
Europe

Mexic o

rev 02
2.3-6 Engine: Components Location
M-Car:
Engine
Performance
Fenix 5 MR
Instructor Guide
1. Manifold Air Temperature Sensor (IAT)

2. Optical Sensor (Engine Speed Sensor)
3. Idle Air Control Valve (IAC)
4. Throttle Position Sensor (TP Sensor)
5. Exhaust Gas Recirculation Soniod (EGR)
6. Knock Sensor
7. Generator B+
8. G103 Ground Point
9. Reverse Lamp Switch
10. O2 Sensor (only unleaded)
rev 02 11. Coolant Temperature Sensor (ECT)
IAC IGN. “ON”
SES
Ignition Coil Distributor
Octane Switch
Throttle Body
CTS Purge Spark

MAT Soleniod Plug
Cooling Fan Relay

MAP Canister
VSS A/C Compressor Relay
A/C Switch Signal Serial Data

TPS
Evaporator Therminstor Main Relay
ACM (TPS, RPM)
Optical Sensor Fuel Fuel

Power Steering Pressure S/W
Engine: ECM Input & Output Schematic
Filter Pump
Head Light “ON” Signal
Fuel Rail
Injector
Engine
= Non-ECI Fuel
Catalytic Converter
Tank
2.3-7
M-Car:
Engine
Fenix 5 MR
Performance
Instructor Guide
rev 02
2.3-8 Engine: ECM Input and Output
M-Car:
Engine
Performance Input Control Output
Fenix 5 MR
Instructor Guide
2. IG Power
3. MAP
4. TPS
5. ECT 1. Injector (Seguential)
6. O2 Sensor 2. SparkTiming
7. IAT 3. IACV
8. Evaporator Thermistor 4. A/C COMP. Clutch Relay
9. VSS (M/T) 5. Fuel Pump Relay
10. Crank Position Signal 6. S.E.S. Lamp
11. Cylinder No 1 Position 7. Cooling Fan (HI, LOW)
Signal 8. Canister Purge Solenoid
12. Knock Senor 9. EGR Solenoid
13. Power Steering Oil 10. Main Relay
Pressure 11. Serial Data (DLC)
14. Headlight ON Signal
15. A/C Request Signal
16. CO Adjuster (Leaded)
EP-55
17. Octane Select
19. Ground
rev 02
Engine: Oxygen Sensor 2.3-9
M-Car:
Engine
The Oxygen sensor is used to adjust and maintain preferred engine air/fuel Fenix 5 MR
mixtures to better control exhaust emissions and fuel economy. Instructor Guide
Most automotive Oxygen sensors are made of Zirconium. This ceramic
material will produce a voltage in response to the amount of unused oxygen
in the exhaust stream. It does this by comparing the amount of oxygen in the
exhaust to the amount of oxygen in the air. When the exhaust is lean
(excess air), the sensor produces a low voltage (near zero volts). When the
exhaust is rich (excess fuel), it produces a high voltage (up to one volt).
For the sensor to work correctly, it needs a good source of outside air for
reference and a source of exhaust temperatures of at least 360 degrees C
(600 degrees F).
Typically, an unheated sensor is open to the atmosphere at the outer shield
and is heated by the exhaust gas. The ECM compares the voltage from the
oxygen sensor to the values programmed into it. If the air/fuel ratio is lean, it
adds fuel; and if the air/fuel ratio is rich, it reduce fuel to keep the engine
running properly.
The ECM uses Oxygen Sensor information for:
• Open loop/closed loop criteria
• Ideal air/fuel ratio EP-56
Oxygen Sensor Element
21% Oxygen 21% Oxygen
0.6V 0.3V
0% 2%
Oxygen Oxygen
More Voltage Less Voltage

Output Output
Different Oxygen Levels
rev 02
M-Car:
Engine
Performance
Location
Fenix 5 MR Just below the exhaust manifold on the exhaust pipe
Instructor Guide
Inspection
Signal
Ground
EP-57
Reference Voltage
1. Connect O2 sensor
2. Measure the voltage between signal line and ground.
Spec ified Voltage 450 m V
Signal Voltage
1. Maintain idle RPM while the ECT is over 80° C (176° F)
2. Measure the O2 sensor signal between terminal 17 and 18 of the ECM.
Spec ified Voltage 100 m V - 900 m V
If the measured value is not within the above specifications, the cause may be
in the wiring, the O2 sensor, the ECM or the engine.
rev 02
M-Car:
Engine
The ECT sensor is a two-wire sensor. It is threaded into the engine coolant Fenix 5 MR
jacket in direct contact with the engine coolant. The coolant sensor contains Instructor Guide
a thermistor and provides the ECM with coolant temperature readings. The
ECM supplies a 5-volt reference signal to the ECT sensor through a dropping
resistor.
When the sensor becomes hot, it has lower resistance, which the ECM
detects as lower voltage. This is called Negative Temperature Coefficient
(NTC). The ECM uses the ECT information to make the needed calculations
for:
• Rich fuel delivery in cold conditions

• Advanced Ignition timing in cold conditions
• The knock sensor system
• Idle RPM control in cold conditions
• Torque converter clutch application
• The canister purge solenoid
• Cooling fan operation
• The A/C Compressor
EP-58
Location
ECT Location
rev 02
M-Car:
Engine
Performance
Inspection
Fenix 5 MR
Instructor Guide
SIG
5V REF
OrB MAP, Knock
Sensor, ECT,
Evaporator,
Temperature Sensor
Ground
at the connector terminal.
Reference value: 4.8 - 5.2 V

If the above value is not measured, the sensor wiring may be open or shorted
or the ECM has malfunctioned.
EP-59
2. Connect the sensor and measure the voltage at the signal terminal
according to engine temperature.
• Reference value at normal operating temperature: 0.2 - 0.5 V
3. Disconnect the sensor and measure the resistance of the sensor.

• Check with the Service Manual for acceptable resistance values.
ECT Resistance
15 ± 0.25°C (59°F) 4.1 ~ 4.7 KΩ
20°C (68°F) 3 ~ 4 KΩ
80°C (176°F) 332Ω

128 ± 0.25°C (262°F) 77.7 ~ 84 Ω
rev 02
Engine: Intake Air Temperature Sensor (IAT) 2.3-13
M-Car:
Engine
The IAT sensor is a two-wire NTC sensor that measures the temperature of Fenix 5 MR
air before it enters the combustion chamber. It is a kind of thermistor that Instructor Guide
provides a varying voltage signal to the ECM depending on its varying
resistance.
The ECM supplies a 5-volt reference signal to the IAT sensor through a
resistor. Sensor resistance and resulting sensor voltage become high
together when the sensor is cold.
Air temperature readings are of particular importance during cold engine
operation. A reading of the manifold or the intake air temperature is used by
the ECM to:
• Adjust the air/fuel ratio in accordance with air density, particularly during
cold engine operation or when the exhaust manifold and fuel are below
normal operating temperature.
• Control spark advance and acceleration enrichment.
• Determine when to enable the EGR and CCCP. (Some Applications)
Location
EP-60
rev 02
M-Car:
Engine
Performance Description
Fenix 5 MR • Sensor Type: Negative Temperature Coefficient
Instructor Guide • Location : Air Cleaner
Inspection
ECM
20 5V ref
2
Signal
IAT
1 46
temperature.
temperature.
Temp. (°F) 14 23 32 41 59 68 77 86 95
Temp. (°C) -10 -5 0 5 15 20 25 30 35
Resistance (k 9,20 7,27 5,80 4,65 3,06 2,50 2,06 1,70 1,41
Voltage (V) 3,96 3,75 3,52 3,28 2,79 2,54 2,29 2,06 1,84
rev 02
Engine: Throttle Position Sensor (TPS) 2.3-15
M-Car:
Engine
The TPS is a three-wire variable resistor (potentiometer) mounted on the Fenix 5 MR
throttle body and operated by the throttle valve shaft. When the throttle valve Instructor Guide
is closed, the ECM reads a low voltage signal. When the throttle is wide open,
the ECM reads a high voltage signal. The voltage signal changes according to
the throttle position, about 0.5 volts at idle and about 4.5 volts at wide open
throttle (WOT).
The TPS signal is one of the parameters used by the ECM to calculate:
• Fuel Delivery
• Torque Converter Clutch (TCC) Application
• Transmission Shifting Schedule
• EVAP Control
• Ignition Ttiming
• EGR
• A/C
Location
EP-61
rev 02
2.3-16 Engine: Throttle Position Sensor (TPS)
M-Car:
Engine
Performance
Inspection
Fenix 5 MR
Instructor Guide
45
19
46
between terminal A and B of the connector.
EP-62
Reference Voltage 4.9 - 5.2 V
If the above value is not measured, the sensor wiring may be open or
2. IGN ON, connect the sensor, measure the signal voltage between
terminal C and ground according to the throttle valve position.
Throttle Position Signal Voltage

Idle 0.4 - 0.8 V
Wide Open 4.1 - 4.8 V
3. If the reference value is not measured, disconnect the sensor and

measure the resistance of each terminal.
Total Resistance (ter. A - B) 7Ω

Closed (ter. B - C) 2.6 Ω
W.O.T (ter. B - C) 8.3 Ω
rev 02
Engine: Vehicle Speed Sensor (VSS, for M/T) 2.3-17
M-Car:
Engine
The VSS provides vehicle speed information to the ECM. Fenix 5 MR
It alternatively grounds the signal wire while the speedometer cable is turning. Instructor Guide
The ECM calculates the vehicle speed based onthe time between the ON/
OFF pulses. This information is also displayed by the vehicle speedometer.
Location
The VSS is located in the IP cluster. It is
connected to the transaxle and driven by
a cable and gear.
VSS
EP-63
Inspection
VSS
(Cluster)
Reed
S/W
rev 02
2.3-18 Engine: Vehicle Speed Sensor (VSS, for M/T)
M-Car:
Engine
1. IGN ON, disconnect the sensor and measure the voltage between the
Performance
terminal “A2” and “A8”.
Fenix 5 MR
Instructor Guide
Supply Voltage 11 - 13 V
If the above value is not measured, the fuse or the wiring may be open,
shorted, disconnected or the ground may be faulty.
between terminal “A7” and ground. (Isolate the signal wire from other
circuits)
Reference Voltage 5 V ref
If the reference value is not measured, inspect the ECM for open wiring.
3. IGN ON, connect the sensor and measure the signal voltage between
terminal A7 and ground to see if it changes while the VSS shaft is turned
slowly.
Reference Voltage Cycle between below 1V and above 12 V
If the above value is not measured, the sensor is faulty
* VSS vs Signal (HZ)
VSS (mph) 0 12 25 37 50 62 75 87 99 112
VSS(km/h) 0 20 40 60 80 100 120 140 160 180
HZ 0,00 7,07 14,15 21,23 28,31 35,38 42,46 49,54 56,61 63,69
rev 02
Engine: Manifold Absolute Pressure Sensor (MAP) 2.3-19
M-Car:
Engine
The MAP sensor is a three - wire sensor. It is located on the dash and Fenix 5 MR
connected directly to intake manifold pressure (vacuum). The MAP sensor Instructor Guide
measures changes in intake manifold air pressure. The ECM uses this
information from the MAP to calculate fuel and spark timing.
The Manifold absolute pressure is the opposite of manifold vacuum. The
MAP is low when vacuum is high (e.g. at closed throttle). When the engine is
not running, the manifold is under atmospheric pressure and the MAP sensor
registers barometric (BARO) pressure.
The BARO pressure reading is used during engine start-up for fuel delivery
calculations as well as during engine running for fuel and spark calculations.
The ECM updates its BARO pressure reading when the ignition is cycled and
when the TPS is at wide open throttle.
The ECM uses MAP information for:
• Fuel delivery
• Canister purge solenoid
• Barometric pressure readings
EP-64
Location
MAP Sensor Location
rev 02
2.3-20 Engine: Manifold Absolute Pressure Sensor (MAP)
M-Car:
Engine
Performance
Inspection
Fenix 5 MR
Instructor Guide MAP Sensor
Intake
Manifold
5V REF
MAP SIG
MAP, Knock Sensor,
ECT, Evaporator,
Temperature Sensor
Ground
Electrical Test
1. IGN ON, disconnect the sensor, and measure the voltage between the
terminal “A” and “C” of the connector to see if reference voltage registers.
Reference Voltage 5.1 ± 0.36 V
2. IGN ON, connect the sensor, measure the voltage between terminal “B”
and ground (Isolate the signal wire from other circuits)
Signal Voltage 4.7 - 5.0 V
3. Run the engine at idle and measure the signal voltage between terminal
“B” and ground. (Engine should be warmed-up with no load)
Reference 1.0 - 1.5 V Idle

Voltage 4.5 - 5.0 V WOT
Functional Test
1. IGN ON, connect the sensor, then connect the vacuum pump to the
sensor vacuum terminal and measure the signal voltage between
terminal “B” and ground as vacuum changes.
Vacuum Pump Vacuum Pump

Signal Voltage Signal Voltage
Pressure Pressure
102 KPA 40 KPA
4.859 - 5.043 V 1.521 - 1.683 V
14.7 psi 5.8 psi
94 KPA 15 KPA
4.438 - 4.600 V 0.122 - 0.382 V
13.6 psi 2.2 psi
rev 02 Note: Any sizeable difference indicates a faulty sensor.
Engine: Knock Sensor 2.3-21
M-Car:
Engine
The knock sensor is used to detect engine detonation, allowing the ECM to Fenix 5 MR
control spark timing based on the knock sensor signal. The amplitude and Instructor Guide
frequency of the knock sensor signal depends on the amount of knock being
detected.
The ECM contains a non-replaceable knock filter called a signal-to-noise
enhancement filter module. This filter module in the ECM determines whether
knock is occurring by comparing the signal level on the knock sensor circuit
with the voltage level on the noise channel.
The noise channel allows the ECM to reject any false knock signal by
recognizing normal engine mechanical noise. Normal engine noise varies
depending on engine speed and load. When the ECM determines that there
is abnormally low voltage level on the noise channel, a DTC(s) will be set.
Location
EP-65
Knock Sensor Location Knocking Signal on Acceleration
rev 02
M-Car:
Engine
Performance Inspection
Fenix 5 MR
Instructor Guide
Knock Sig
Knock Shield
Ground
Knock
Sensor
Because the knock sensor has high resistance, it is difficult to inspect the
sensor with its resistance value. Instead, it can be checked by determining if it
generates voltage when you tap it on a hard surface.
Make sure to chekc the tightening torque of the bolt.
Ter. 1 - 2 ∞
Resistance Ter. 1 - 3 ∞
Ter. 2 - 3 ∞
Output voltage 18 ~ 34 mv/g ( 5 Khz)

achieved.
rev 02
M-Car:
Engine
When the evaporator temperature drops to 0° (32° F) or below, its core can Fenix 5 MR

Item Condition
Driving
ON 73ZLWKLQVHF
73 ! 966 N P
K
Sudden Accel
ON 9.4% < TP < 10% for 6 sec
Evap Temp
ON Evap Temp > 2.45
OFF ECT ¡ Ã 115
ECT
ON ECT ¡ Â 112
OFF RPM ¡ Â 640 or RPM ¡ Ã 66
EP-66
RPM
ON 990 ¡ Â RPM ¡ Â 54
Location

M-Car:
Engine
Performance
Fenix 5 MR Inspection
Instructor Guide Evaporator
Temperature
Sensor
EVA SIG
Ground
EP-67 REF Voltage 4.8 - 5.2 V
rev 02
M-Car:
Engine
When a driver turns the steering wheel, the engine RPM should increase Fenix 5 MR
engine RPM.
Inspection
When turning the steering with high effort to one side or the other, the Power
Steering Pressure switch will provide a ground signal to terminal 37 of the
ECM
Power Steering
Oil Pressure
Switch
(35 Bar)
(508 psi)
EP-68
Location
rev 02
M-Car:
Engine
Performance
Location
Fenix 5 MR
Instructor Guide
1. Clip
2. Injector
3. O-Rings
Injector Specifications
ER-69
Application 0.8 L SOHC
1.35 ± 4% (g/sec)
Static Flow Rate
.005 ± 4% (m3/sec)
Dynamic Flow Rate 2.565 ± 4% (g/sec)

(WOT) .010 ± 4% (m3/sec)
Single Hole,
Spray Type
Single Spray
Fuel Cut-Off: 6750 RPM (Immediate) / 6495 (Re-wetting)
rev 02
M-Car:
Engine
Fenix 5 MR
Instructor Guide
MAIN
RELAY
FUEL
PUMP
ER-70
the power supply to see if battery voltage is present. If not, check the
engine compartment fuse and wiring.
2. Disconnect the injector, install a test lamp or a volt meter on both

terminals of the connector, and then crank the engine. If the measured
voltage does not change or the test lamp stays on, the wiring between
the injector and the ECM is shorted to ground.
If the test lamp stays off, the wiring between the ECM terminals 30, 1 and
4 and the injector is open or the ECM has malfunctioned.
3. Connect the injector, turn the ignition on and measure the voltage of the
ECM terminals 30, 1 and 4. If battery voltage is not measured, the
injector coil or the wiring is open or the connector is not connected
properly.
rev 02
M-Car:
Engine
Performance
Fuel Injection Timing
Fenix 5 MR Crank Operation Stroke
Instructor Guide Angle
Cylinder No 0~180 180~360 360~540 540~720
1 Power Exhaust Intake Compression
2 Exhaust Intake Compression Power Exhaust
3 Intake Compression Power Exhaust Intake
Electronic
Spark Timing
No. 1 Position
Crankshaft
Position Signal
Injector No. 1
ER-71 Injector No. 2
Injector No. 3
rev 02
Engine: Distributor Ignition System 2.3-29
M-Car:
Engine
The ignition system triggers the ignition coil to spark off the compressed Fenix 5 MR
mixture inside the combustion chamber. Instructor Guide
The ignition system consists of a battery, ignition coil, distributor, ignition wire
and spark plug. This system uses an optical sensor to cut off the primary
current by the ECM. The ECM receives the position the No. 1 cylinder
together with the cank angle signal to control the ignition timing for maximum
engine performance.
EP-72
No. 1 RPM Shield

Cylinder Signal Ground
Signal
1. Battery 5. Ignition Coil 9. Spark Plug

2. Main Fuse 6. Distributor 10. ECM
3. Ignition Switch 7. Distributor Rotor
4. Fuse 8. Optical Sensor
rev 02
2.3-30 Engine: Distributor Ignition System
M-Car:
Engine
Performance
Location
Fenix 5 MR
Instructor Guide
Ignition Coil
The ignition coil is an iron cored, closed, magnetic type of transformer that
generates high voltage(15,000~25,000V), which is used for High Energy
Ignition (HEI) systems.
EP-73 Application Value
Primary Coil 1.2 ± 0.2 Ω
Secondary Coil 12.1 kΩ
Resistance of high tension cable:
REF Value 2.5 – 12 kΩ
rev 02
Engine: Distributor Ignition System 2.3-31
M-Car:
Engine
Spark Plug Performance
Maker
Fenix 5 MR
NGK
Instructor Guide
* Unleaded
BPR5EY-11 (NGK)
RN9YC4 (Champion)
WR8DCX (Bosch)
Type
* Leaded
BPR5EY (NGK)
RN9YC (Champion)
WR8DC (Bosch)
* Unleaded
- 1.1 (.043 in): BPR5EY-11, RN9YC4
Gap (mm)
- 1.2 (.047 in): WR8DCX
* Leaded : 0.8 (.031 in)
Maintenance Every 20,000 km (12,427 mi)
Distributor
The distributor provides high tension voltage to each spark plug in order 1-3-
2. It consists of the distributor cap, rotor, optical sensor, slit type disk, photo
diode, LED, crank angle sensor and distributor housing
EP-74
Light
Emitting
Diode No. 1 TDC Sensor Slit
Crankshaft
Position
Signal Slit Running Disk
(54 hole)
Photo No. 1
Diode Cylinder
Engine RPM
ECM
rev 02
2.3-32 Engine: Exhaust Gas Recirculation (EGR)
M-Car:
Engine
Performance
General Operation
Fenix 5 MR The solenoid valve is powered by the battery through the main relay, while the
EGR is controlled by ON/OFF signals from the ECM.
Instructor Guide
If octane value is 83, the EGR system will disengage and the ECM will control
spark timing and fuel injection, accordingly.

ECT ≥ 25
IAT ≥ 20
RPM < 4768 RPM
MAP < 101.3 Kpa (1.5 psi)
TP > 0% , Not WOT
Location
EGR Modulator
EP-75
EGR Valve EGR Solenoid
rev 02
Engine: Exhaust Gas Recirculation (EGR) 2.3-33
M-Car:
Engine
Fenix 5 MR
Instructor Guide
Relay
EGR
Solenoid
Specification
EP-76
Application Values
Operating 70 ± 5L/min at 125mmHg
3
Vacuum (2.4 ± 2f /min) at (4.9 Hg)
rev 02
M-Car:
Engine
Performance
General Operation
Fenix 5 MR The IAC valve is located in the throttle body. It has a movable pintle at one
end, driven by a small electric stepper motor, which is capable of moving in
Instructor Guide
exact, measured amounts called steps.
The ECM uses the IAC valve to control idle rpm. It performs this function by
changing the pintle position in the idle air passage of the throttle body. This
varies the airflow around the throttle plate when the throttle is closed.
During closed throttle, the ECM continuously compares actual idle rpm with
the programmed idle rpm and adjusts the IAC valve accordingly to achieve
the desired idle rpm. In some applications, the ECM also adjusts ignition
timing to control idle speed even more precisely.
To determine the desired position of the IAC pintle during idle or deceleration,
which is indicated by closed throttle position (0% throttle angle), the ECM
refers to the following inputs:
• Battery Voltage
• ECT
• TPS
• Engine Load (MAP, A/C compressor)
• Engine rpm
EP-77
• Vehicle Speed
Location
IAC
ECM Pintle
Throttle Valve
Intake
Air
Throttle
Body
rev 02
Engine: Idle Air Control (IAC) Valve 2.3-35
M-Car:
Terminal
Engine
Pintle Step RPM
Cycle 1 2 3 4 Performance
Max open 204 Increase Fenix 5 MR
Max close 0 Decrease 1 + - + - Instructor Guide
2 + - - +
3 - + - +
4 - + + -
5 + - + -
6 + - - +
HI
LOW
HI
LOW
1. Measure the voltage between IAC connector pins A through D and

ground while revving the engine. If the voltage is not present, the wiring
between the step motor and the ECM is open.
Terminals Voltage
A ↔ Ground
B ↔ Ground
Cycles 0.5V and 12V
C ↔ Ground
D ↔ Ground
2. Turn the ignition switch off, disconnect the IAC and then measure the
resistance of IAC valve.
Terminals Resistance
A↔ B 40 - 80 Ω
C↔D 40 - 80 Ω
A,B,C,D ↔ Ground ∞Ω
3. If the valves are found to be outside specifications, replace the valve. rev 02
M-Car:
Engine
Performance Resetting IAC Valve
Fenix 5 MR 1: Resetting IAC valve is needed when:
Instructor Guide
• Battery replacement
• ECM replacement
• IAC replacement
• Fault code clearing
2: Malfunction of IAC valve may induce:

• Poor Start
• Unstable Idle rpm
• A/C compressor clutch may be disengaged (A/C “ON”)
3: IAC Valve Resetting procedure with using IG key

1. IG switch OFF and disconnect battery “-” terminal for over 10
seconds
2. IG switch “ON” for 3~5 seconds
3. IG switch “OFF” for 3~5 seconds
4. IG switch is “ON” and cranking (ENG running)
5. Cycle the A/C switch and move shift lever several times.
Notice : Do not attempt to pull or push on the pintle of the IAC valve
that has been in service.
rev 02
Solenoid M-Car:
Engine
Performance
General Operation Fenix 5 MR
The basic evaporative emission (EVAP) control uses a charcoal canister Instructor Guide
combustion process.
The CCCP is enabled of disabled depending on the following

conditions:
Parameter Enable Condition Disable Condition
Fuel Control Mode Closed Loop Open Loop
ECT > 40 °C or 104°F < 35 °C or 95°F
TP >0% WOT
Vehicle Speed > 0 km/h (0 mph)
Engine Not decel
Battery 8 V - 19 V
Vehicle 0.8 L
3
ON Min 30 L / min (1.1 ft /min)
Vent Flow Rate
3
OFF Below 0.05L / min (.02 ft /min)
Resistance 30 - 60 Ω
rev 02
M-Car: Solenoid
Engine
Performance
Fenix 5 MR Location
Instructor Guide The CCCP is located inside the engine compartment
CCCP Canister
Inspection
EP-78
Main
Relay
CCP
Solenoid
Resistance (25° C / 77°F) 30 - 60 Ω
rev 02
ECM & Diagnosis: Engine Control Module 2.3-39
M-Car:
Engine
ECM Type Performance
Fenix 5 MR
Model Maker ID Remark
Instructor Guide
FENIX 5MR SASCO 2S(W/E) 55 pins
Connector for Octane Value

Octane
95 91 87 83
Value
Terminal "22" Open Open Ground Ground
Terminal "25" Ground Open Open Ground
Location
The ECM is located under the dash on the driver side. There are no
serviceable parts in the ECM. The calibration data is stored in Programmable
Read Only memory (PROM).
FENIX 5MR
rev 02
2.3-40 ECM & Diagnosis: Service Engine Soon Lamp
M-Car:
Engine
Performance
Fenix 5 MR
Instructor Guide
1. Diagnostic terminal (C) is
grounded (A)
2. Ignition Switch “ON” and
Engine stop
3. Count lamp flashing on the
cluster
Check 4. If there is no trouble, the
SES lamp will be OFF 4
seconds after the ignition
switch is turned ON.
ON
OFF
ON
OFF
5. In order to erase trouble codes after repairs, Do one of the follows

• Remove Ef19(15A) for more than 10 seconds
• Disconnect the Battery (-) terminal for more than 10 seconds
• By Erasing command of Scanner
rev 02
ECM & Diagnosis: DTC 2.3-41
M-Car:
Engine
DTC Function Remark
Performance
Manifold Absolute Pressure Sensor Low Fenix 5 MR
0105
Manifold Absolute Pressure Sensor High Instructor Guide
Intake Air Temperature Sensor Low
0110
Intake Air Temperature Sensor High
0115
Throttle Position Sensor Low
0120
Throttle Position Sensor High
0130 Oxygen Sensor not toggling
0201 No1. Injector shorted to Ground/Battery
0320 Engine Speed Optical Sensor
0340 Camshaft Optical Sensor
Canister Purge Solenoid shorted to Ground
0440
Canister Purge Solenoid shorted to Battery
0500 Vehicle Speed Sensor Error
Idle Air Control shorted to Ground
0505
Idle Air Control shorted to Battery
0560 Variable Manifold manifold short to battery
0601 ECM Error
1100 Air/Fuel Correction
1110 Adaptive A/F Correction
1500 A/C Evaporator Thermistor short to Ground / Battery
Main relay shorted to Ground
1610
Main relay shorted to Battery
A/C Cut shorted to Ground
1620
A/C Cut shorted to Battery
Low Speed Cooling Fan Low
1630
Low Speed Cooling Fan Low
High Speed Cooling Fan Low
1631
High Speed Cooling Fan Low
0325 Kock Sensor failure
EGR Solenoid shorted to Ground
0400
EGR Solenoid shorted to Battery
1600 Immobilizer Error
rev 02
CAPÍTULO 3
CAJA DE CAMBIOS AUTOMÁTICA
Introducción............................................................................................... 5
Número de identificación para caja de cambios automática..................... 6
Características especiales......................................................................... 7
Especificación............................................................................................ 8
Diagramas de cambios.............................................................................. 9
Palanca de slección y rango de cambios................................................. 11
Bomba de aceite, enfriador...................................................................... 12
Unidad de engranajes planetario............................................................. 13
Embragues y frenos................................................................................. 14
Primer engranaje...................................................................................... 15
Segundo engranaje.................................................................................. 16
Tercer engranaje...................................................................................... 17
Cuarto engranaje...................................................................................... 18
Reversa.................................................................................................... 19
Válvulas y solenoides............................................................................... 20
Introducción.............................................................................................. 25
Primer engranaje(Rango L)...................................................................... 26
Primer engranaje(Rango L)...................................................................... 27
Primer engranaje(Rangos D y 2).............................................................. 28
Segundo engranaje.................................................................................. 30
Tercer engranaje...................................................................................... 32
Cuarto engranaje...................................................................................... 34
Engranaje de reversa............................................................................... 36
Control de bloqueo................................................................................... 38
Visión del control TCM............................................................................. 41
Control de cambios.................................................................................. 42
Control de bloqueo................................................................................... 43
Controlador de caja automática............................................................... 44
Señales de entrada.................................................................................. 46
Señales de salida..................................................................................... 59
Carta de códigos de problemas............................................................... 62
Visualización de códigos de problemas................................................... 63
Borrado de códigos de problemas........................................................... 64
Inspección básica..................................................................................... 65
Condición y nivel de fluidos de caja automática....................................... 66
Prueba de desfase de tiempo.................................................................. 68
Prueba de calado..................................................................................... 69
Presión de aceite...................................................................................... 70
Prueba de rango "P"................................................................................ 72
Remplazo de fluidos de caja de transmisión automática......................... 73
Precauciones............................................................................................ 74
Inspección de desarmado/desmontaje..................................................... 77
Mantenimiento del cuerpo de válvula....................................................... 78
Rodamientos............................................................................................ 79
Circuito de presión de aceite.................................................................... 80
Diagnóstico de problemas/síntomas........................................................ 83
Herramientas especiales........................................................................ 105
M-Car:
Automatic
Introduction ................................................................................................ 5 Transaxle
AT Identification Number ........................................................................... 6
Instructor Guide
Special Feature ......................................................................................... 7
Specification .............................................................................................. 8
Shift Diagrams ........................................................................................... 9
Select Lever & Shift Range ..................................................................... 11
Oil Pump, Cooler ..................................................................................... 12
Planetary Gear Unit ................................................................................. 13
Clutches and Brakes ............................................................................... 14
1st Gear ................................................................................................... 15
2nd Gear ................................................................................................. 16
3rd Gear .................................................................................................. 17
4th Gear ................................................................................................... 18
Reverse ................................................................................................... 19
Valves and Solenoids ............................................................................. 20
Introduction .............................................................................................. 25
1st Gear (“L” Range) ................................................................................ 26
1st Gear (“L” Range) ................................................................................ 27
1st Gear (“D” and “2” Ranges) .................................................................. 28
2nd Gear ................................................................................................. 30
3rd Gear .................................................................................................. 32
4th Gear ................................................................................................... 34
Reverse Gear .......................................................................................... 36 AT-1
Lock-Up Control ...................................................................................... 38
TCM Control Overview ............................................................................ 41
Shift Control ............................................................................................ 42
Lock-Up Control ...................................................................................... 43
AT Controller ........................................................................................... 44
Input Signals ........................................................................................... 46
Output Signals ......................................................................................... 59
Trouble Code Chart ................................................................................. 62
Trouble Code Display .............................................................................. 63
Trouble Codes Erase ............................................................................... 64
(Continued) rev 02
3-4
M-Car:
Table of Contents
Automatic
Transaxle Basic Inspection ...................................................................................... 65
Instructor Guide AT Fluid Level and Condition .................................................................. 66
Time Lag Test .......................................................................................... 68
Stall Test .................................................................................................. 69
Oil Pressure ............................................................................................ 70
“P” Range Test ......................................................................................... 72
AT Fluid Replacement ............................................................................. 73
Precautions ............................................................................................. 74
Disassembling Inspection ....................................................................... 77
Valve body Maintenance ......................................................................... 78
Bearing .................................................................................................... 79
Oil Pressure Circuit ................................................................................. 80
Symptom Troubleshooting ....................................................................... 83
Special Tool ........................................................................................... 105
rev 02
Introduction 3-5
M-Car:
Automatic
This newly developed automatic transmission is light and compact for small
Transaxle
vehicles to provide smooth operation, swift driving, and improved fuel
consumption. Its electronically-controlled shifting timing and oil pressure Instructor Guide
have resulted in delicate gear change for various driving conditions including
throttle position and vehicle speed. Thus, smooth driving at all speed has
been realized.
In this transmission, a symmetrical three-element, single-stage and two-
phase of torque converter is employed. The transmission consists of 2 single
planetary gears, 3 sets of disc clutches, 1 set of disc brakes, 1 set of band
brake, 1 set of one-way clutch, etc.
Front carrier Rear carrier Input shaft Torque converter

Low one-way clutch Low clutch
High clutch Low & reverse brake
Reverse clutch Oil pump
2-4 brake Output gear
Front sun gear
Front ring gear
AT-2
Rear sun gear

Rear ring gear
Parking gear
Reduction gear
Idler gear
Differential assembly
Final gear
rev 02
3-6 AT Identification Number
M-Car:
Automatic
Transaxle
Instructor Guide
AT-3
Serial Number
Year: 2000
Month: May (Jan - Sep: 1-9, Oct X, Nov: Y, Dec: Z)
rev 02
Special Feature 3-7
M-Car:
Automatic
Item Feature Remarks Transaxle
Instructor Guide
- 4 forward speed with two planetary Light & Compact
gears
1. Power Train - Control Element
control element Wet, Multi-disc clutches : 3 sets
Band brake : 1 set
Wet, Multi-disc brakes :1 set
One-way clutch :1 set
2. Engine 0.8L MPI Max : 110Nm (1.0L)

3. Torque
Lock-up control Electronic
Converter
4. Cooling Remote cooler not
AT case built-in : Water cooling
sysytem needed
5. Line pressure
Electronical Duty control Smooth operation
control
Smooth operation
: Line pressure
- ATF Temperature sensor
: Lock-up
: Gear shift
6. Sensor
Smooth operation
- Input Shaft Speed sensor (ISS)
: Lock-up
- Output Shaft Speed sensro (VSS)
- Overdrive signal (O/D) On/Off Switch Gear shift control

7. Input signal - Air conditioner signal
Smooth operation
(Engine power loss->Shock->Line P
: Line pressure control
down)
- D or 2 range -> L range 1st gear : Low&Reverse Gear
8. Engine Brake - D range 3/4th gear -> 2 range 2nd gear : 2 range 1st gear OWC
- D range 4th gear -> O/D Off 3th gear : Less effective
rev 02
3-8 Specification
M-Car:
Automatic
Item Data Remarks
Transaxle
4-forward and 1 reverse speed, with
Instructor Guide A/T type
planetary gears, Electronic
WKUHHSRLQWERVVZLWKORFNXS Turbine outside
Torque converter
Type control (Symetrical 3-element, 1- diameter
step 2 phase) :
Stall Torque (ts) 1,92
4th gear only
Lock-up condition
(Available on the 3rd, during O/D
Oil Capacity 1L
Oil
Type Trochoid oil pump
pum
LOW/C 6 Control element
Multi-disc clutch : 3
Number of
Hi/C 3
clutches
sets
REV/C 2 Band brake : 1 set
Multi-disc brake :1
L&R/B 6
set
Servo size 56-35 One-way clutch :1
Output teeth 38
Four-point gear
Idle teeth 50
A/T data
Reduction teeth 19
Final teeth 68
Primary reduction
1,316 IDL/OPG
ratio
Final reduction ratio 3,579 FINAL/RDCN
IDL/OPG *
if (Total reduction ratio) 4,709
FINAL/RDCN
1st 2,914 Fr-Sun teeth=28
Rr-Sun teeth=35
2nd 1,525 Fr-Pinion
Gear ratio
teeth=23
3rd 1
Rr-Pinion
4th 0,725 teeth=16
Fr-Ring teeth=74
Rev 2,642 Rr-Ring teeth=67
Lubricating system Forced oil delivery from oil pump
4.4L : Level gage
MaticD : ESSO JWS3314 = 2 : 1
ATF lowest (Including
(Assembling Line Mix Ratio)
T/C oil 1L)
ATF replacement No need to change ESSO JWS3314
Dry / With MaticD /
Weight 45kg / 46kg / 49kg
Full
rev 02
Shift Diagrams 3-9
M-Car:
Automatic
D range Transaxle
Instructor Guide
Acceleration opening angle
Vehivle speed (km/h)
Lock Up
Acceleration opening angle
4rd gear
lock-up OFF
4rd gear
3rd gear
lock-up ON
lock-up OFF 3rd gear
lock-up ON
Vehivle speed (km/h)
rev 02
3-10 Shift Diagrams
M-Car:
Automatic
Transaxle
2 Range
Instructor Guide
L range
rev 02
Select Lever & Shift Range 3-11
M-Car:
Parking position
Automatic
- The output shaft of the transmission is mechanically locked.
- Engine can be cranked.
Transaxle
P - The key interlock mechanism of the ignition key is released. Instructor Guide
- When the ignition key is ON, shifting to another range is possible by pressing
the
ST button while depressing the brake pedal.
Reverse position
R
SØ - Selected for Reverse gear
Neutral position
N
×Ø - Engine can be cranked.
Normal driving position
- Shifted automatically between 1st and 2nd, 2nd and 3rd, and 3rd and 4th gears
D in
response to the vehicle speed and throttle angle.
×T (Gear is limited up to the 3rd when O/D is OFF.)
Selected for engine brake effect or limit shifting up to the 2nd.
2
×T - Shifted automatically between the 1st and 2nd gears.
1st gear position
L - Selected when climbing a steep slope or powerful engine braking is desirable
when driving downhill.
Select lever
The select lever is a floor type. “N” “D” can be selected freely.
“P”ó”R”, “N”ð”R”, “D”ð”2", and “2”ð”L” are selected by pressing the
button.
pq: Shift with pressing the button / ñò: Shift without pressing the button
Notice : Be sure to observe the followings when operating the shift lever.
Otherwise, it may cause the automatic transmission to be internal-
damaged or the vehicle to start suddenly.
1. “P” should be selected only when the vehicle has completely stopped.
2. Shifting from forward ranges (“D”, “2”, or “L”) to reverse (“R”) and vice
versa should happen only when the vehicle is in a complete standstill.
3. If the engine is rurning at high speed while “N” or “P” is selected, do not
select another range.
4. While driving the vehicle, do not coast down in the “N” range nor repeat
shifting to the “N” range.
Shift range
Shift Schedule
Range
O/D ON O/D OFF
D 1Ù2Ù3Ù4 1Ù2Ù3Õ4
2 1Ù2Õ3Õ4
L 1Õ2Õ3Õ4
rev 02
3-12 Oil Pump, Cooler
M-Car:
Automatic
Transaxle
Oil Pump
The trochoid oil pump is installed on the input shaft side of the AT case. Oil
Instructor Guide pump is operated by the torque converter sleeve case. Therefore, the
lubrication is not carried out when the engine stops.
AT-4 Oil Cooler

The built-in water-cooled oil cooler is installed on the AT case.
rev 02
Planetary Gear Unit 3-13
M-Car:
Automatic
The planetary gear unit is used to shift the gear position to forward, reverse,
Transaxle
or neutral. This unit consists of the sun gear, the planetary carrier, and the
internal (ring) gear. Different engagement combination of each planetary gear Instructor Guide
of in the front and rear side enables forward, backward shifting.
1. Sun gear
2. Pinion gear
3. Internal gear(Ring gear)
4. Planetary carrier
A. When the sun gear is locked, planetary

carrier rotates slower than internal gear.
B. When the planetary carrier is locked,
sun gear rotates faster than internal
gear, in reverse direction.
C. When the internal gear is locked, sun
gear is faster than planetary carrier.
AT-5
Clutch and Brakes

To shift gears via the planetary gear unit, clutches and brakes are used to
engage and lock the components of the front and the rear respectively.
Clutches and brakes, except the one-way clutch, are operated by oil pressure
switched by the shift valves, the solenoid valves and the oil passage in the
valve body .
Low Lo & Rev. High Reverse 2-4 brake Lo one-way

Shift position
clutch brake clutch clutch band clutch
P
R x x
N
4th gear x x
3rd gear x x
2nd gear x x
1st (“D”, “2” range) x x*
1st (“L” range) x x Eng Brake
* Locked only while accelerating
rev 02
3-14 Clutches and Brakes
M-Car:
Automatic
Transaxle
1. Low clutch
The low clutch engages the rear internal gear and the front planetary
Instructor Guide carrier.
2. Low & reverse brake
- The low & reverse brake locks the front planetary carrier in reverse
gear.
- This brake operates in the 1st gear in the “L” range along with the
low clutch to lock the rear internal gear, which enables engine brake
in the “L” range.
3. High clutch
The high clutch engages the front planetary carrier and the input shaft,
which operates in the 3rd and 4th gears.
4. Reverse clutch
The reverse clutch engages the front sun gear and the input shaft, which
operates along with the low & reverse brake in reverse gear.
5. Low one-way clutch
The low one-way clutch prevents reverse rotation of the front carrier and
the rear internal gear which are engaged together by the low clutch. This
operates just mechanically. Because the front carrier and the rear internal
gear with low clutch is able to rotate clockwise, engine brake does not
occur.
6. 2-4 brake and brake servo
The 2-4 brake and brake servo lock the front sun gear. These operate in
the 2nd and the 4th gear. The 2-4 brake operates via the 2-4 brake servo
of which the engagement and release sides line pressure is applied to.
The brake operates when line pressure is applied only to the
engagement side. The 2-4 brake does not operate when line pressure is
applied to both of the engagement and release sides.
7. Lock-up clutch
The lock-up clutch inside the torque converter locks up under the
appropriate conditions in 3rd and 4th gears.
rev 02
1st Gear 3-15
M-Car:
Automatic
1st Gear (L Range) Transaxle
Front Rear
Instructor Guide
Internal gear Rotates CW (ni rpm) Locked
Carrier Locked Rotates CW (ncrpm)
Sun gear Rotates CCW (nsrpm) Rotates CW (nsrpm)
Input: Rear sun gear Output: Rear Carrier ns > nc
ns > nc indicates that output is the reduction to input.

Engine brake can occur by the low clutch and the low & reverse brake.
Operating components
• Low clutch: engages the rear internal gear and the front carrier
• Low & Reverse brake: locks the front carrier
(ns: Revolution Sun gear, nc: Revolution Carrier, ni: Revolution Internal gear)
(CW:Clockwise / CCW:Counterclockwise)
1st gear (D and 2 ranges)

Operating conditions are almost same as the 1st gear in the “L” range.
However, since the L & R brake does not operate, engine brake is not AT-6
available.
Low & Reverse Brake One-Way Clutch

Low Clutch
Reverse
2-4 Band Clutch
Clutch
High Clutch
1. Input Shaft (rear sun gear) 4. Front Sun Gear

2. Front Internal Gear 5. Rear Internal Gear
3. Front Carrier 6. Rear Carrier
rev 02
3-16 2nd Gear
M-Car:
Automatic
Transaxle Front Rear
Instructor Guide Internal gear Rotates CW (ni rpm) Rotates CW (ni rpm)
Carrier Rotates CW (ncrpm) Rotates CW (ncrpm)
Sun gear Locked Rotates CW (nsrpm)
Input: Rear sun gear

Output: Rear Carrier
ns > nc
ns > nc indicates that output is the reduction to input.

In 2nd gear, the front sun gear is locked and the front carrier rotates
clockwise. Therefore, the front internal gear rotates faster than in 1st gear,
and output rotation in 2nd gear becomes faster than in 1st gear.
• Low Clutch: engages the rear internal gear and the front carrier
• 2-4 Brake: locks the front sun gear
AT-7
2-4 Band
Low Clutch
Reverse
Clutch
High Clutch

rev 02
3rd Gear 3-17
M-Car:
Automatic
Front Rear Transaxle
Internal gear Rotates CW (nirpm) Rotates CW (nirpm) Instructor Guide

Sun gear Rotates CW (nsrpm) Rotates CW (nsrpm)
Output: Rear Carrier
ns = ni = nc
In the 3rd gear, the rear sun gear and the rear internal gear rotates same
speed, which means the rear planetary unit rotates as one unit.
The input and output shafts are linked directly.
• Low Clutch: engages the rear internal gear and the front carrier
• High Clutch: engages the the front carrier and the input shaft

2-4 Band AT-8
Low Clutch
Reverse
Clutch
High Clutch

rev 02
3-18 4th Gear
M-Car:
Automatic
Transaxle Front Rear
Instructor Guide
Internal gear Rotates CW (ni rpm) Rotates CW (ni rpm)
Sun gear Locked Rotates CW (nsrpm)
Input: Front carrier

Output: Front internal gear
n c < ni
In 4th gear, the front sun gear is locked and the front carrier rotates. The
front internal gear rotates faster than the front carrier. Therefore, output
rotation is faster than input rotation.
• High Clutch : engages the the front carrier with the input shaft
• 2-4 Brake : locks the front sun gear
AT-9
2-4 Band
Low Clutch
Reverse
Clutch
High Clutch

rev 02
Reverse 3-19
M-Car:
Automatic
Front Rear Transaxle
Internal gear Rotates CCW (ni rpm) Rotates CCW (ni rpm) Instructor Guide
Carrier Locked Rotates CCW (ncrpm)

Sun gear Rotates CW (nsrpm) Rotates CW (nsrpm)

Output: Front internal gear
ns > ni , 0 > ni (minus Speed)
In the “R” gear, the front carrier is locked and the front sun gear rotates
clockwise. The front internal gear rotates counterclockwise. Therefore, the
output shaft rotates counterclockwise.
• Low & Reverse Brake: locks the front carrier
• Reverse Clutch: engages the front sun gear and the input shaft
AT-10
2-4 Band Brake
Low Clutch Reverse
Clutch
High Clutch

rev 02
3-20 Valves and Solenoids
M-Car:
Automatic
Transaxle
1. Pressure regulator valve
The pressure regulator valve regulates the oil pump discharge pressure to the
Instructor Guide set-up pressure.
AT fluid which has been regulated to the set-up pressure lubricates the
rotating parts, the torque converter and the inside of the valve.
The oil pressure changes in response to the driving range and throttle
position.
2. Manual valve
The manual valve shifts the line pressure paths directly via the select lever.
3. Pilot valve
The pilot valve keeps the oil pressure steady which fluctuates according to
driving conditions.
The oil pressure passing through this valve is called the pilot pressure. This
oil pressure is delivered through each solenoid valve to the operating side of
the shift valves and the pressure modifier valve.
AT-11
Shift solenoid A, B
Pressure modifier valve
Line Pressure
Pilot Line pressure solenoid
Valve (Signal Pressure: 4 kg/cm²)
Drain
rev 02
Valves and Solonoids 3-21
M-Car:
Automatic
4. Pressure modifier valve Transaxle
The pressure modifier valve is operated by the pilot pressure which is
regulated by the line pressure solenoid valve. Instructor Guide
The oil pressure which has passed through this valve is called the modifier
pressure. The modifier pressure operates the pressure regulator valve and the
accumulator control valve. The line pressure changes in response to driving
conditions by this operation.
Pressure Pressure regulator

Pilot
Modifier Accumulator Control
Pressure Modifier
Valve Pressure
Pilot Pressure from

(line pressure solenoid)
5. Shift valve A
The shift valve A switches the line pressure applied to the shift valve B and
the engagement side of the 2-4 brake servo. This valve is operated by
switching the pilot pressure. AT-12
Pilot pressure switching is controlled by the shift solenoid valve A.
6. Shift valve B
The shift valve B switches the line pressure applied to each clutch and brake,
as well as the pilot pressure applied to the neutral shift valve and the lock-up
control valve. This valve is operated by switching the pilot pressure.
Pilot pressure switching is controlled by the shift solenoid valve B.
Manual Valve Shift Solenoid A

ON: 1-2 OFF: 1-Close
3-Close 2-Drain
4-7 3-7
5-Close 4-Close
Low & 6-Drain 5-6
reverse Brake Shift Shift 2nd Brake Servo
High Clutch Valve Valve engagement side
Low Clutch B B
Shift Solenoid B
ON: A-D OFF: A-Close
Drain Drain
B-F B-E
Shift Solenoid B Shift Solenoid B C-Close C-F
E-Drain D-Drain
rev 02
3-22 Valves and Solonoids
M-Car:
Automatic
Transaxle
7. Shift solenoid valve A
The shift solenoid valve A controls the pilot pressure which operates the shift
Instructor Guide valve A.
The valve ON opens the path for the pilot pressure; OFF closes it.
8. Shift solenoid valve B

The shift solenoid valve B controls the pilot pressure which operates the shift
valve B.
The valve ON opens the path for the pilot pressure; OFF closes it.
ON OFF
Pilot Pressure To Shift Valve Pilot Pressure
9. Servo release timing valve

The servo release timing valve sets up the timing that the line pressure is
AT-13 applied to the release side of the 2-4 brake servo in accordnce with the timing
that the line pressure is applied to the low clutch and the high clutch, while
shifting from 2nd gear to 3rd, or from 4th gear to 3rd gear occurs.
• When oil pressure is applied to only 1, 2 through 3 is opened and 1 is
closed.
• When oil pressure is applied to only 2, 1 through 3 is opened and 2 is
closed.
• When oil pressure is applied to 1 and 2, 1 through 3 is opened and it is
applied to the release side of the 2-4 brake servo.
High Clutch
Low Clutch
Servo Release
1
Timing Valve
2-4 Brake
2 servo Release
From Shift Valve
rev 02
Valves and Solonoids 3-23
M-Car:
Automatic
10. Line pressure solenoid valve Transaxle
The line pressure solenoid valve regulates the pilot pressure applied to the
pressure modifier valve in response to the throttle position. The valve is duty- Instructor Guide
controlled.
Pilot Pressure Pressure Modifier Valve
Line Pressure Solenoid Valve
11. Line pressure relief valve

Prevents the line pressure applied to the manual valve from increasing above
certain limits.
12. Accumulator
This unit relieves abnormal line pressure rise, applied to each brake and
clutch. The line pressure is controlled by the accumulator control valve
pressure applied on the opposite side of the accumulators.
13. Accumulator control valve AT-14

The accumulator control valve regulates the accumulator control pressure,
which is the line pressure (back pressure) applied to each accumulator. This
valve is operated via the pilot pressure regulated by the pressure modifier
valve.
1. Line Pressure
2. Accumulator Control Pressure
3. To each Accumulator
4. Modifier Pressure
5. Accumulator Control Valve
rev 02
3-24 Valves and Solonoids
M-Car:
Automatic
Transaxle
14. Lock-up solenoid valve
The lock-up solenoid valve regulates the pilot pressure which operates the
Instructor Guide lock-up control valve during lock-up.
The valve is duty-controlled.
15. Lock-up control valve

The lock-up control valve controls oil pressure, applied to the lock-up clutch
in the torque converter, via the pilot pressure regulated by the lock-up
solenoid.
Lubrication Torque Converter
Shift Valve
Lock-up Control Valve B
Line Pressure Lock-up Solenoid

AT-15
Pilot Pressure
16. Neutral control valve
The neutral control valve absorbs fluctuations of line pressure applied to the
low clutch.
Low Clutch
From Shift Valve B
Modifier Pressure
rev 02
Introduction 3-25
M-Car:
Automatic
To shift gears, the line pressure and the pilot pressure are used.
Transaxle
Line pressure which operates clutches and brakes is controlled by the
Instructor Guide
manual valve and the shift valves A and B.
Pilot pressure, which is line pressure regulated by the pilot valve, operates the
shift valves A and B and the lock-up control valve. It is controlled by the shift
solenoid valves A and B and the lock-up solenoid.
Line pressure is regulated by the pressure regulator valve in response to the
pressure modifier valve (throttle position) and the manual valve (selector lever
position). For control details, refer to the sections of the pressure regulator
valve, the pressure modifier valve and manual valve in “Valves and solenoids.”
Manual Valve
Drain Drain Line Pressure

Shift Solenoid A
Pilot
Valve
Solenoid Solenoid
ON Line Pressure
OFF Solenoid
Pressure
Modifier Valve
Drain Shift Valve B AT-16

Shift Solenoid B
Solenoid Solenoid
ON OFF
Pressure Accumulator
Regulator Valve Control Valve
Check Ball ShiftSolenoid

Servo
Release 1st Gear
Timing 2nd Gear
Valve
3rd Gear On
4th Gear Off
Reverse Low & High 2-4 Brake 2-4 Brake Low
Clutch Reverse Clutch Servo Servo Clutch
Brake Release Engagement
Side Side
rev 02
3-26 1st Gear (L Range)
M-Car:
Automatic
Transaxle
Line pressure
Manual Valve Shift Valve A
Instructor Guide
Shift Valve B Low Clutch
Low&Reverse Brake
Pilot pressure
Pressure Regulator Valve
Pilot Valve Shift Solenoid A (ON) Shift Valve A
Shift Solenoid B (ON) Shift Valve B
Since the shift solenoid valve A and B are ON, the pilot pressure operates the
shift valves A and B.
Since the manual valve is positioned for the “L” range, oil pressure which has
passed through the shift valve A and B is applied to the low & reverse brake.
Therefore, line pressure passes through the manual valve and the shift valve
A and B, and then operates the low clutch and the low & reverse brake. Since
AT-17 the low & reverse brake operates, engine brake occurs when the accelerator
pedal is released.
rev 02
1st Gear (L Range) 3-27
M-Car:
Automatic
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
-Throttle Pressure
-Torque Convertor AT-18
Applying Pressure
17. Neutral Control Valve

18. Servo Release Accumulator
19. 1-2 Modulator Valve
20. Shift Valve A
1. Torque Converter (Lock-Up Release) 21. Shift Valve B
2.T orque Converter (Lock-Up Engagement) 22. Lock-Up Solenoid
3. Low & Reverse Brake 23. Torque Converter Relief Valve
4. Low Clutch 24. Pilot Valve
5. High Clutch 25. Line Pressure Solenoid
6. Reverse Clutch 26. Shift Solenoid B
7. 2-4 Brake Engagement 27. Shift Solenoid A
8. 2-4 Brake Release 28. Manual Valve
9. 1-2 Accumulator 29. Throttle Pressure Accumulator
10. Servo Release Timing Valve 30. Pressure Modifier Valve
11. Neutral Shift Valve 31. Pressure Regulator Valve
12. Low Clutch Accumulator 32. Accumulator Control Valve
13. Rear Lubrication 33. Line Pressure Relief Valve
14. Front Lubrication 34. Oil Pump
15. Oil Cooler 35. Discharge
rev 02
16. Lock-Up Control Valve 36. Suction
3-28 1st Gear (D and 2 Ranges)
M-Car:
Automatic
Transaxle
Line pressure
Instructor Guide
Manual Valve Shift Valve B Low Clutch
Pilot pressure
Since the shift solenoid valve A and B are ON, the pilot pressure operates the
shift valves A and B.
Therefore, line pressure passes through the manual valve and the shift valve
A and B, and then operates the low clutch.
Unlike in the case of “L” range, the low & reverse brake does not operate and
the rear internal gear, engaged to the front carrier by the low clutch, is locked
only against counterclockwise rotation by the low one-way clutch; however, it
AT-19 can rotate clockwise. Therefore, engine brake does not occur when the
accelerator pedal is released.
rev 02
1st Gear (D and 2 Ranges) 3-29
M-Car:
Automatic
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
-Throttle Pressure
Applying Pressure

20. Shift Valve A
2. Torque Converter (Lock-Up Engagement) 22. Lock-Up Solenoid
16. Lock-Up Control Valve 36. Suction rev 02
3-30 2nd Gear
M-Car:
Automatic
Transaxle
Line Pressure
Instructor Guide Manual Valve Shift Valve A 2-4 Brake Servo Engagement Side
Pilot Pressure
Pilot Valve Shift Solenoid A (ON)
Since the shift solenoid valve A is OFF, pilot pressure is blocked and the shift
valve A does not operate.
Since the shift solenoid valve B is ON, the shift valve B operates.
Line pressure passes through the manual valve to shift valves A and B, and in
turn operate the 2-4 brake servo engagement side and the low clutch.
AT-21
rev 02
2nd Gear 3-31
M-Car:
Automatic
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
-Throttle Pressure
AT-22
-Torque Convertor
Applying Pressure

20. Shift Valve A
rev 02
3-32 3rd Gear
M-Car:
Automatic
Transaxle
Line pressure
Instructor Guide Manual Valve Shift Valve A 2-4 Brake Servo Engagement Side
Servo Release
Timing Valve 2-4 Brake Servo Releas Side
High Clutch
Pilot pressure
Pilot Valve Shift Solenoid A (ON)
Shift Solenoid B (ON)
Line pressure passes through the manual valve to the shift valves A and
B.
Line pressure which has passed through the shift valve A is applied to the
AT-23
2-4 brake servo engagement side and the shift valve B.
Line pressure which has passed through shift valve B is applied to the low
clutch and the servo release timing valve engagement side.
Line pressure which has passed through the manual valve to the shift
valve B is applied to the high clutch and the servo release timing valve.
Line pressure which has passed through the servo release timing valve is
applied to the 2-4 brake servo release side and releases the 2-4 brake.
Therefore, the low clutch and the high clutch operate.
rev 02
3rd Gear 3-33
M-Car:
Automatic
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
-Throttle Pressure
-Torque Convertor
Applying Pressure AT-24

20. Shift Valve A
rev 02
3-34 4th Gear
M-Car:
Automatic
Transaxle
Line pressure
Manual Valve Shift Valve A 2-4 Brake Servo Engagement Side
Instructor Guide
Shift Valve B High Clutch
Pilot pressure
Shift Solenoid B (ON)
Line pressure passes through the manual valve to the shift valve A and B.
Line pressure which has sent through the manual valve to the shift valve A
stops there.
Line pressure which has passed through the shift valve B is sent to the high
clutch and the shift valve A.
Line pressure which has passed through the shift valve A is sent to the 2-4
AT-25 brake servo engagement side.
Therefore, the 2-4 brake and the high clutch operate.
rev 02
4th Gear 3-35
M-Car:
Automatic
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
-Throttle Pressure
Applying Pressure

20. Shift Valve A
3-36 Reverse Gear
M-Car:
Automatic
Transaxle
Line Pressure
Instructor Guide Manual Valve Low & Reverse Brake
Reverse Clutch
Line pressure is not applied to the shift valves A and B but to the low &
reverse brake and the reverse clutch directly.
Therefore, pilot pressure and the shift solenoid valves A and B are not
concerned to gear change.
Line pressure is applied to the pressure regulator valve as well, and kept
higher than in forward gear.
AT-27
rev 02
Reverse Gear 3-37
M-Car:
Automatic
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
-Throttle Pressure
AT-28
-Torque Convertor
Applying Pressure

20. Shift Valve A
3-38 Lock-Up Control
M-Car:
Automatic
When the lock-up conditions are met, the lock-up solenoid applies pilot
Transaxle
pressure to the shift valve B. Pilot pressure passing through the shift valve B
Instructor Guide operates the lock-up control valve to drain oil pressure from the lock-up
clutch release side of the torque converter as well as to raise oil pressure at
the engagement side.
The lock-up solenoid is duty-controlled. For control details, refer to the
“Control mechanism” section.
Lock-Up Applied
Lock-up Clutch
Engagement Release
Side Side
Lubricates
Inside
Transmission
Lock-up
Shift
Control Valve
Valve B
Drain
Lock-up
Solenoid
Line Pressure
AT-29
Pilot Pressure
Lock-Up Released
Engagement Release
Side Side
Lubricates
Inside
Transmission
Lock-up Shift
Control Valve Valve B
Lock-up
Solenoid
Line Pressure
Pilot Pressure
rev 02
Lock-Up Control 3-39
M-Car:
3rd Gear Lock-Up Automatic
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
-Throttle Pressure
Applying Pressure

20. Shift Valve A
3-40 Lock-Up Control
M-Car:
Automatic
4th Gear Lock-Up
Transaxle
Instructor Guide
-Line Pressure
-Pilot Pressure
AT-31 -Throttle Pressure
-Torque Convertor
Applying Pressure

20. Shift Valve A
rev 02 16. Lock-Up Control Valve 36. Suction
TCM Control Overview 3-41
M-Car:
Automatic
Item Description Transaxle
1. Shift control 1st through 4th is available in D,2,L range Instructor Guide
2. 4th gear - O/D OFF switch disables 4th gear

prohibition - Low temperature(20
- Lock-up is available in 4th gear

- In O/D OFF, lock-up is available in 3rd gear
3. Lock-up - Low temperature(20
- L/U Duty Solenoid makes smoothing control to reduce
shock in L/U engaging or release
- LP Duty Solenoid reduces shock in shifting

- Line pressure increases for quick engaging in
4. Line pressure
extremely
low temperature
5. Line pressure Air conditioner signal controls line pressure to reduce shock
compensation ,which occurs due to input torque change.
Even in case of input/output component malfunctions, the

least driving should be possible.
6. Fail safe
(In critical fail, 3rd gear fixed hydraulically or
electrically)
7. Mafuncion - Lamp blinking tells mafunction occurred.

Indication - Lamp blinking indicates fail codes by jumping wire
rev 02
3-42 Shift Control
M-Car:
Automatic
Gears are shifted by the solenoid valve A and B, which are controlled by the
Transaxle
AT controller, and the manual valve operated by the select lever.
Instructor Guide
When the select lever is positioned in the “P”, “N” or “R”, gear change is done
mechanically by the manual valve and line pressure.
In other positions, shifting up and down between 1st, 2nd, 3rd, and 4th
gears is controlled by the shift solenoid valve A and B.
Note: If the AT fluid temperature is lower than 20°C, shifting-up to 4th gear is
disabled.
Refer to the previous sections for the power flow mechanism and the oil
pressure circuit for each gear position.
Input Output
Vehicle Speed Signal
Throttle Signal Shift Solenold A
A/C On AT
Controller Shift Solenold B
Oil Temperature Signal
Overdrive Switch Signal Line Pressure Solenoid

AT-32
PNP Switch
rev 02
Lock-Up Control 3-43
M-Car:
Automatic
When certain conditions are met during driving at higher speed than a certain
Transaxle
value in 3rd (overdrive OFF) or 4th (overdrive ON) gear, the AT controller
outputs a signal to the lock-up solenoid to operate the lock-up clutch in the Instructor Guide
torque converter. This is the lock-up control.
Lock-up control is performed by the lock-up solenoid and the lock-up control
valve.
Lock-up control execution conditions

• The shift position must be in the 3rd or the 4th gear.
• The throttle angle and vehicle speed must be within the lock-up control
range.
• The AT fluid temperature must be within the control execution range. (
³ 20°C)
• The shift switch is in the D position.
Conditions for lock-up control prohibition

• The execution conditions are not fulfilled.
Input Output AT-33

Vehicle Speed Signal
Throttle Signal
Oil Temperature Signal AT

Controller Lock-up Solenoid
Shift Switch Signal
Engine Speed Signal
Input Shaft Speed Signal
rev 02
3-44 AT Controller
M-Car:
Automatic
The AT controller is located on the left side of the driver leg room. It sends
Transaxle
output signals to the solenoids in response to input signals from each sensor
Instructor Guide for gear change and lock-up control. If an error is detected, the fail-safe
function starts to work in order to secure a minimum driving performance.
Power Supply (V IGN)
Battery Back Up (V BATT)
IG. SW. PL Duty Sol.

Ground Return
Shift Sol. A
Shift Sol. B
Lu Duty Sol.
Battery No
P Range SW
R Range SW
A/C Relay N Range SW
A/C Cut Signal D Range SW
2 Range SW
L Range SW
Reverse
Lamp
Unit ASSY - CONT
OD Off SW
AT-34
OD Off Lamp
DIAG. SW Vehicle Speed Sensor
DIAG. Lamp
Turbine Sensor
Speed ATF Temperature Sensor

Meter V IGN Sensor GND
A13 VSP Out
Power GND
rev 02
AT Controller 3-45
M-Car:
Automatic
Transaxle
Instructor Guide
48-pin connector
White Gray
(Engine stopped, IGN On)
No Signal Voltage No Signal Voltage

1 PL duty solenoid Battery voltage 25 GND for system 0V
2 GND return 0V 26 P range SW Battery voltage in "P"
3 LU duty solenoid Approx. 0V 27 2 range SW Battery voltage in "2"
4 28
5 29
6 30
7 31
8 GND for sensor 0V 32 Vehicle speed sensor 0 or 12V
9 Turbine rev. sensor 0V 33
10 Power supply Battery voltage 34 L range SW Battery voltage in "L"
11 Power supply Battery voltage 35 D range SW Battery voltage in "D" AT-35
12 Diagnosis lamp Battery voltage 36 R range SW Battery voltage in "R"
13 37
14 38 N range SW Battery voltage in "N"
15 39 Engine rev. signal 0.65V
16 40 VSS out (speed meter)0 or 12V
17 Diagnosis SW Battery voltage 41
18 O/D OFF SW ON : 12V, OFF : 0V 42
19 Battery back up Battery voltage 43 GND for system 0V
20 Shift solenoid B Battery voltage 44
21 Shift solenoid A Battery voltage 45
22 46 Throttle pos. signal 11V
23 47
24 Air conditioner signal Battery voltage 48 ATF temperature sens2.5V, CNT disconnecte
rev 02
3-46 Input Signals
M-Car:
Automatic
Transaxle
Vehicle speed signal
Instructor Guide Description
Vehicle speed sensor is installed in the AT case and detects the rotor teeth in
the differential gear.
This sensor is a hall effect sensor, which generates 0V and 12V alternately.
As the vehicle speed increases, it produces more frequent voltage
alternation, which means higher frequency. The frequency variation signal
is monitored and input as vehicle speed. The vehicle speed and throttle
signals are used as basic data for gear shifting along with TP signal.
Vehicle Speed Sensor
Controller
Pulse Interval
AT-36 Specification
• Air gap: 1.5 ± 0.5mm
• Tightening Torque: 5.9 - 7.8Nm
• Resistance
Voltage
- “D1”-”D2" : ¥
- “D1”-”D3" : ¥
- “D2”-”D3" : ¥
• Pulse
Low Speed High Speed
- Duty: 50%-50% fixed
- Frequency: Increase by speed Time
- Period: 24.16ms at 62.08km/h (Actual measure)
rev 02
Input Signals 3-47
M-Car:
Automatic
Transaxle
Ref V:12V
Instructor Guide
Vehicle
IG. SW. Speed
AT Controller
Sensor
Vehicle Speed Sensor Connector
AT Controller Connector
Inspection
1. Disconnect the sensor connector and IGN ON, check if battery voltage
is supplied to pin D3 of the sensor. AT-37
2. Disconnect the sensor connector, check if battery ground is supplied
to pin D2 of the sensor.
3. Disconnect the sensor connector and IGN ON, check if 12 V is supplied
to pin D1 of the sensor from TCM.
4. Disconnect the sensor connector, and check the sensor resistance
between three pins. They should measure ¡Ä(infinite).
5. Connect the sensor connector, IGN ON and The multi tester should
measure 0V or 12V on the signal wire depending on the rotor position.
6. Move the select lever to the “N” range and engage the parking brake.
7. Lift up the vehicle from the ground.
8. Connect the sensor connector, IGN ON and turn the wheels by hands.
The multi tester should measure 0V and 12V alternately on the signal
wire.
According to speed increasing, the signal frequency should increase.
9. Inspect the signal line battery voltage short or the sensor air gap and the
rotor teeth or TCM internal fault.
rev 02
3-48 Input Signals
M-Car:
Automatic
Transaxle
Input shaft speed signal
The input shaft speed (turbine) sensor detects the high clutch sleeve speed,
which is installed on the mounting (the side cover) at the side of the
transmission case. This sensor is a variable reluctance sensor, which
generates wave pulses. As the turbine speed increases, it outputs bigger
amplitude and higher frequency signals. This signal is used as basic data
for lock-up control and gear ratio calculation.
Specification
• Air gap : 1.5 ± 0.5mm
• Tightening Torque : 5.9 - 7.8Nm
• Resistance : 540W (20°C)
AT-38
• Input Shaft Speed – Output Voltage Chart
RPM 100 200 300 500 950 1000 2000 3000 5000
Voltage (DC) 0,6 1,2 1,6 2,6 4,4 4,7 8,2 11,5 17
Turbine rpm + 3205

Voltage Period = 1.56 msec
Pict to Pick = 7.8V
1 Period 1/12 rev. Low

Speed High Speed
rev 02
Input Signals 3-49
M-Car:
Automatic
Transaxle
AT Instructor Guide
Controller
High Clutch
Shielding Wire
Sleeve
Turbine Sensor
Turbine Sensor Connector
Inspection
1. Disconnect the sensor connector, IGN ON, measure the voltage between
the C1 pin of the turbine sensor and ground. it should be 4.5~5V.
The “C2” and the ground measures 0V
2. Remove the turbine sensor connector.
AT-39
Measure the resistance of the turbine sensor. (540 W at 20°C)
3. Connect the sensor connector, IGN ON. 0V is checked on the signal line.
4. Move the select lever to the “N” range and engage the parking brake.
5. Lift up the vehicle from the ground.

6. Connect the sensor connector, Idle the engine.
The multi tester should measure some output voltage from the sensor
signal line. (refer to RPM-Voltage chart)
According to speed increasing, the signal amplitude and frequency
should increase.
7. Inspect the signal line battery short or the sensor air gap and the high
clutch sleeve or TCM internal fault.
rev 02
3-50 Input Signals
M-Car:
Automatic
Transaxle
Shift position signal
This shift switch is installed on the manual shaft which applies the battery
voltage to the AT controller in response to the select lever position. Then the
controller detects the positions of the select lever and the manual valve.
This signal is used to determine the appropriate driving gear for the vehicle
speed. This switch also works as a starter inhibit switch.
High
(Battery Voltage)
Low
(approx. OV) Selected
Other Terminal Terminal
Voltage Voltage
Adjustment
1. Position the select lever assembly to “N”.
2. Loosen the shift switch fixing bolt.
3. Fix the select lever assembly by inserting a 3 mm pin (drill) into the
location hole of the select lever assembly and the shift switch.
AT-40 4. Tighten the fixing bolt.
Tightening torque: 3.2 Nm (33 kgf cm)
Inspection
Check the shift switch for the continuity in each position corresponding to
the following table.
Terminal Mark
Shift Position
rev 02
Input Signals 3-51
M-Car:
Automatic
Shift Switch Coupler Transaxle
Instructor Guide
AT Controller Back Lamp

Shift Switch
Shift Switch Connector
1. Remove the switch connector, IGN ON and measure the voltage of the
terminal A1. It should be 12V.
2. Remove the switch connector, IGN ON and measure the voltage of the
terminal A2 through A8 between ground. It should be 0V.
3. Remove the connector of the shift switch. AT-41
Inspect the switch continuity depending on the switch continuity
chart.
4. Install the shift switch connector, IGN ON and measure the voltage on
each terminal changing the shift lever position.
It should measure 12V at appropriate shift lever position selected.
5. Inspect the signal line ground short or TCM internal fault.
rev 02
3-52 Input Signals
M-Car:
Automatic
Transaxle
AT Fluid temperature signal
This sensor detects the AT fluid temperature, installed on the valve body. This
sensor is a NTC (Negative Temperature Coefficient) type, that is, temperature
goes up, resistance goes down. Resistance of the sensor is sensed as
voltage signal and used to judge the proper shifting point, 4th gear and lock-
up control criterior, and line pressure control.
Resistance
Oile Temperature
Specification [ R = R20 x EXP{B(1/T-1/T20)} ]

• Resistance
* Legend
20°C: approx. 3.5 kW
R : Resistance
AT-42
80°C: approx. 0.17 kW R20 = 2.5KOhm at 20°C
B=3520 (constant)
T20 = 293 = 273 + 20 (Absolute
temperature)
* EX) At -40°C, R = 50KOhm
• Temperature-Voltage Chart
T e mpe rature (°C ) -40 -30 -20 -10 0 10 20 30 40

Voltage (V) 2,5 2,4 2,3 2,1 2 1,8 1,6 1,3 1,1
T e mpe rature (°C ) 50 60 70 80 90 100 110 120 130

Voltage (V) 0,9 0,7 0,6 0,5 0,4 0,3 0,2 0,2 0,1
rev 02
Input Signals 3-53
M-Car:
Automatic
Transaxle
Ref V:2.5V
Instructor Guide
AT Controller
Oil Temperature
Shift Solenoid Sensor
Coupler
Valve Body
Shift Solenoid Connector AT Controller Connector
Inspection
1. Disconnect the sensor connector, IGN ON and measure the voltage of
the terminal “B6”. It should measure 2.5V.
2. Disconnect the sensor connector, IGN ON and measure the voltage of
the terminal “B7”. It should measure 0V
3. Disconnect the sensor, and check the sensor resistance.
20°C: approx. 3.5 kW AT-43
4. Connect the sensor connector, IGN ON and check the signal voltage
based on the Temperature-Voltage chart.
5. Inspect TCM internal fault.
rev 02
3-54 Input Signals
M-Car:
Automatic
Transaxle
Engine speed signal
The engine speed signal is input from the engine controller, which is
frequency modulation. This signal is used as basic data for lock-up control.
Specification
1 Period=2/3 rev. 1 Period=2/3 rev.

Low Speed High Speed
AT *TCU Engine
AT-44 Controller Ref V: 12V Controller
PullUp R: 5.6kΩ
AT Controller
rev 02
Input Signals 3-55
M-Car:
Inspection Automatic
1. Remove ECM connector, IGN ON and check if 12V is checked on
Transaxle
the signal wire from TCM. Instructor Guide
2. Inspect idle RPM and RPM response in the engine data list with the
scan-100.
3. Connect ECM, IGN ON and check if 0.65V is measured on the signal
wire with a multimeter.
4. Idle the engine, check signal voltage with multimeter, it should be
about 6V. If you accel the engine, then its frequency will increase.
5. Inspect the signal line battery voltage short or ECM/TCM internal fault.
rev 02
3-56 Input Signals
M-Car:
Automatic
Transaxle
The throttle position signal
The throttle signal is sent from the engine controller to the AT controller after
converted into duty signal. As the throttle opening angle increases, the time
ratio of the “LOW” side increases.
Specification
• Frequency : 64Hz (15.625ms)
• PWM Duty (ECM to TCM signal)
- Idle : 8% ± 2% (active-low)
- WOT : 76% ± 3% (active-low)
Duty Ratio = T1/T0

AT-45
OFF Duty
• TP angle & ECM TP signal data relation

TP output = Vout/Vref x 100
(Vout : TP sensor output voltage, Vref : TP sensor reference voltage)
T P Angle (°)
T P output M in T ype M ax
12% (Idle) 6 8 10
90% (W O T) 82 84 86
rev 02
Input Signals 3-57
M-Car:
Automatic
Transaxle
AT Controller Engine Instructor Guide

Ref V: 12V Controller
Pull-Up R:
5.6KΩ Throttle Position Sensor
Inspection
1. Remove ECM connector, IGN ON and check if you can measure
battery voltage on the signal line.
2. With the Scan-100, check if ECM receives the normal TP signal from
the TP sensor.
3. Connector ECM, IGN ON and check signal voltage by a multimeter
With TP 12 %, it should be about 11V. With TP 90%, about 2.4V.
4. Inspect the signal line battery voltage short or ECM/TCM internal fault.
AT-46
rev 02
3-58 Input Signals
M-Car:
Automatic
Transaxle
Overdrive signal
Overdrive switch is installed on the select lever. Shifting-up to the 4th gear,
Instructor Guide which is the over drive, is disabled when this O/D OFF switch is ON, which
makes the 4th gear down-shifted to the 3rd gear and the O/D OFF indicator
ON.
High
(Battery Voltage)
Low
(approx. 0V)
O/D Allowed O/D Not Allowed
(Switch OFF) (Switch ON)
Air conditioner signal

Description
The engine controller sends the control signal to the air conditioning clutch
relay and to the AT controller as well.
While the air conditioning clutch is operating; that is, the air conditioner signal
AT-47 is “Low (approx. 0V)”, the line pressure solenoid is controlled based on this
signal.
A/C ON/OFF changes engine torque. TCM controls the line pressure
solenoid according to this changed engine torque in order to get appropreate
line pressure and reduce shifting shock.
Specification
• TCM ref voltage : 12V
• TCM pull-up Resistor : 5.6k¥Ø
• TCM A/C signal
- A/C OFF : 12V High
(Battery Voltage)
- A/C ON : 0V
Low
(approx. 0V)
Air Conditioner Air Conditioner
ON OFF
rev 02
Output Signals 3-59
M-Car:
Automatic
Shift solenoid A, B signal Transaxle
Description Instructor Guide
These two shift solenoids, which are normally Closed ON/OFF types, control
shifting up and down in combination with each other.
Shift Solenoids Terminal Voltage
High
(Battery Voltage)
Low 1st 2nd 3rd 4th

(approx. 0V)
Shift solenoid A ON OFF OFF ON
Solenoid OFF Solenoid ON
Shift solenoid B ON ON OFF OFF
Inspection
1. IGN ON, measure voltage of the shift solenoid A&B control lines
between ground. (CNT Connected / Disconnected : 12V / 12V)
2. IGN OFF, remove the solenoid connector.
Check the resistance of shift solenoid A and B between ground.
Resistance : 25W (20°C)
3. IGN OFF, remove the solenoid connector. AT-48
Apply battery voltage to the terminal of the shift solenoid A or B.
You should hear the operation clicking sound inside the TM case.
4. Driving the vehicle, check solenoid ON/OFF according to gear position.
5. Inspect the solenoid wire battery voltage short or TCM internal fault.
AT Controller Shift Solenoid A
Shift
Solenoid Shift Solenoid B
Coupler Valve Body
Shift Solenoid AT Controller Connector
rev 02
3-60 Output Signals
M-Car:
Automatic
Transaxle
Line pressure solenoid signal
Duty control signal regulates throttle pressure applied to the pressure
modifier valve.
• Duty : 0~ 95%
• Frequency : 50Hz Valve
• OFF-High pressure Opening
Angle
• ON-Low pressure
Duty OFF - Time Rattio
Inspection
1. IGN ON, measure voltage of the line pressure solenoid high line.
(CNT Connected / Disconnected : 0V / 12V)
2. IGN ON, measure voltage of the line pressure solenoid low line.
Check the solenoid resistance between pin “B3” and “B5”
Resistance : 2.9W (20°C)
AT-49 4. Check the solenoid control voltage according to driving condition.
5. Inspect the solenoid high line battery voltage short or TCM internal fault.
6. Inspect if the solenoid valve mechanically stuck
AT Controller Line Pressure

Solenoid
Shift
Solenoid
Coupler Valve Body
Shift Solenoid Connector AT Controller Connector
rev 02
Output Signals 3-61
M-Car:
Automatic
Lock-up solenoid signal Transaxle
Description Instructor Guide
This signal operates the lock-up solenoid to execute lock-up control. The
duty signal is output when lock-up is applied.
• Duty : 0~ 95%
• Frequency : 50Hz
Inspection
1. IGN ON, measure voltage of the lock-up solenoid control line.
Check the resistance of the lock-up solenoid.
Resistance: 13W (20°C)
3. Check the solenoid control voltage according to lock-up condition.
4. Inspect the solenoid control line ground short or TCM internal fault.
5. Inspect if the solenoid valve mechanically stuck.
AT-50
Lock-Up
AT Controller
Solenoid
Valve Body
Shift Solenoid AT Controller Connector
rev 02
3-62 Trouble Code Chart
M-Car:
Automatic
Transaxle DTC Item Conditions Fail-safe control
Instructor Guide - Considers the previous range as
the
No input signal
current one.
Shift switch - Prohibits lock-up.
55 (Select position
- Determines shift position
switch)
Multiple signal inputs according to the following priority:
from the shift switch “D”>“N”>“P”>“R”>“2”>“L”
- Prohibits lock-up.
Open circuit occurred
Considers oil temperature as 80
AT Fluid durIng driving
17 temperature - Lock-up and 4th gear are
sensor Open/short circuit disabled.
- Line pressure control
- Line pressure control
15 Turbine sensor No input signal - Lock-up is controlled based on
engine and output revolution.
No input signal or
- 3rd gear fixed
Vehicle speed signal input problem
22 - Line pressure control
sensor occurred during
driving
Engine speed
44 No input signal Engine speed = 0
signal
Mechanical or
41 Lock-up clutch Hydraulic Prohibits lock-up.
Malfunction
- the lock-up solenoid OFF.
43 Lock-up solenoid Open/short circuit
Line pressure - the line pressure solenoid OFF.
48 Open/short circuit
solenoid - Line pressure control
- 3rd gear fixed
53 Shift solenoid A Open/short circuit
- 3rd gear fixed
58 Shift solenoid B Open/short circuit
- Prohibits lock-up
Throttle position
Out of range - Shift control
sensor
54 - Line pressure control
Throttle signal
Abnormal pulse width - Prohibits lock-up.
wire
Line Pressure - Sets the line pressure solenoid
75 GND return wire Solenoid GND Open OFF.
circuit - Line pressure control
rev 02
Trouble Code Display 3-63
M-Car:
Automatic
Display of diagnostic codes Transaxle
The diagnostic codes are indicated by flashing of the DIAG LAMP. In order to
read the diagnostic codes, ground the DIAG SW(TCM “17” pin or DLC Instructor Guide
“L”) of the AT controller. Identify the diagnostic codes via the flashing of the
DIAG LAMP as shown in the diagram below.
If there is no designated fault

Code 12 will repeat to be displayed
-ON-
-OFF-
If there is assigned fault code

Firstly, code 12 flashes three times, and then the flashing, like the diagram
below, occurs three times (example : code 32) for each code in ascending
order of the diagnostic codes.
When all diagnostic codes have been displayed , the signal flashing cycles by
returng to the code 12.
-ON-
AT-51
-OFF-
Fault indication
When a fault is detected, the DIAG LAMP(Power Lamp) flashes automatically
as shown below. (1.25Hz)
-ON-
-OFF-
rev 02
3-64 Trouble Codes Erase
M-Car:
Automatic
Error codes in TCM can be erased as following flow.
Transaxle
Instructor Guide * Operate the select lever as following.
(within 10 sec : if not, erasing process can not be guaranteed)
1. Stop the engine.
2. Select “R” range for at least 2 sec
3. Turn ON the ignition key
4. Select “N” range at least 2 sec
5. Select “D” range at least 2 sec
6. Select “2” range at least 2 sec
rev 02
Basic Inspection 3-65
M-Car:
Automatic
It is necessary to check whether or not the basic automatic transmission
Transaxle
maintenance has been carried out.
Instructor Guide
The maintenance details are outlined in the “Primary check” and
“Maintenance”.
1. Power supply and voltage check
The battery voltage must be 10 - 14V when the engine is stopped.
2. AT fluid check
Check level and AT fluid condition.
3. Stall test
Check the engine speed at stall in each range, and check the overall
performance of the automatic transmission and the engine.
4. Oil pressure test
Measure the line pressure when idling and when the engine has stalled,
and check the functions of each component.
5. Ignition timing and idling engine speed check
Adjust these if they are not within the specified ranges.
If a problem occurs such as a “fluctuating engine speed”, troubleshoot
the engine first.
6. Select linkage check and adjustment
7. Throttle sensor check and adjustment
8. Road test
A road test is carried out to assess the problem properly and as a post
maintenance check.
9. Electrical wiring check
Check that the connectors fit securely, that the connector has neither
become rusty nor accumulated grime, that the terminals are secure and
have not become distorted and that no parts have become loose or
damaged.
rev 02
3-66 AT Fluid Level and Condition
M-Car:
Automatic
Transaxle
Procedure
1. Drive the vehicle until the ATF reaches normal condition (70 - 80°C),
Instructor Guide usually 5 km driving in the city.
2. Park the vehicle on level ground and apply the parking brake. In engine
idling, move the select lever slowly from P through L and back to
P.
3. In engine idling, pick up the oil level gauge, wipe it clean with a paper
towel and insert it back to check the AT fluid level. The level of the fluid
should be within the range specified on the level gauge. If the level is too
low, add the recommended AT fluid. At this time, check the fluid for odor,
foreign matter, or discoloration.
Note:
• The fluid level changes according to the ATF temperature. Be sure to
follow the procedure above when carrying out this check.
• Before this check, wipe out dirt and grime from the level gauge to prevent
polluting inside the AT transmission.
• Recommended AT fluid : ESSO JWS3314
Judgmental criteria
1. AT fluid level
The AT fluid level should be within the specified range. If the level is low,
check the transmission for leakage visually.
2. AT fluid condition
Normal AT fluid is red and of moderate viscosity. If the fluid has
become dark, much viscous, or smells abnormally (a burnt smell), carry
out the road, stall, and oil pressure tests. If the vehicle operates normally,
change the fluid and carry out the road test again.
If the fluid has become white in color, the oil cooler probably leaks.
rev 02
AT Fluid Level and Condition 3-67
M-Car:
Automatic
Transaxle
Oil Level (mm: Hot - Hi Level = 0mm
Instructor Guide
High Side
Low Side
Oil Temperature
Center
Test Oil : Idemitsu Matic D : Esso JWS 3314 (mix ratio 2:1)
AT-52
rev 02
3-68 Time Lag Test
M-Car:
Automatic
Note:
Be sure to start to measure the time after when the engine is fully
Transaxle
•
Instructor Guide warmed up.
• For another testing after one testing is finished, be sure to wait for at
least one minute after moving the select lever back to N range.
Procedure
1. Previously check the AT fluid level
2. Block the vehicle with the scotches at the front and rear wheels securely,
apply the parking brake, and depress the foot brake.
3. Start the engine and move the select lever from “N” to “D”. Measure the
time it takes from this moment until shift shock is felt using a stop watch.
4. By the same way, measure the time lag from “N” to “R” range.
• Time lag standard:

- “N” range - D” range : 0.8sec
- “N” range - R” range : 0.8sec
Judgmental criteria
Result Probable cause
-Low line pressure

Time lag "N" to "D" > -Low clutch slip
0.8s -Oneway clutch slip
-Damage of the low clutch piston oil seal
-Low line pressure
-Low & Reverse brake slip
Time lag "N" to "R" >
-Reverse clutch slip
0.8s
-Damage oft the above brake or clutch piston oil
seal
rev 02
Stall Test 3-69
M-Car:
Note: Automatic
• Do not continue the stall test for more than 5 seconds at a time.
Transaxle
• After a test, Cool the transmission by idling for at least 30 seconds. Instructor Guide
Procedure
1. Check the AT fluid level and condition.
apply the parking brake.
3. Install the engine tachometer.
4. Depress the foot brake with the left foot. Start the engine. Move the
select lever to “D” and depress the accelerator pedal while monitoring the
engine speed. Quickly read the engine stall RPM at the point that the
engine speed becomes constant(stall point).
5. Perform this test in “R” and “L” as well.
Note: Stall speed : 2850 RPM
Judgmental criteria
Result Probable cause
- Insufficient engine output
Lower than the standard in all ranges
- Faulty torque converter
- One-way clutch slip
Higher than the standard in “D” and “2”
- Low clutch slip
Higher than the standard in “D”, “2”, and “L - Low clutch slip
- Reverse clutch slip
Higher than the standard in “R”
- Low & reverse brake slip
Higher than the standard in “R” and “L” - Low & reverse brake slip
- Low line pressure
Higher than the standard in all ranges - Faulty oil pump
- Faulty pressure regulator
rev 02
3-70 Oil Pressure
M-Car:
Automatic
Transaxle
Procedure
Instructor Guide 2. Attach special tool A to the oil pressure check hole of the transmission
case.
Note: ATM oil pressure gauge set : DW-240-010
apply the parking brake.
4. Start the engine and depress the foot brake. Read oil pressure in “D” and
“R” ranges in idling and in stall condition.
Note:
• Ensure no oil leak after installing the oil pressure gauge.
• Do not continue the stall condition for more than 5 seconds at a
time.
• Be sure to cool the transmission, idling for at least 30 seconds
between test cycles.
Oil pressure standard
Engine operation "D" range "R" range
Idling [KPa (kg/cm²)] 470 (4.8) 600 (6.1)

Stall [KPa (kg/cm²)] 1030 (10.5) 1310 (13.4)
Judgmental Criteria
Probable cause
Result
Range “D” “R”
Higher than the standard

- Faulty valve body
in idling / stall condition
- Damaged reverse
- Faulty oil pump
clutch
Lower than the standard - Damaged low clutch
piston oil seal
in idling / stall condition piston
- Damaged low &
oil seal
reverse
rev 02
Oil Pressure 3-71
M-Car:
Automatic
Oil Pressure Port Transaxle
Instructor Guide
Line Pressure Port
Servo Apply Pressure
AT-53
Reserve Clutch High Clutch

Pressure Port Pressure Port
rev 02
3-72 P Range Test
M-Car:
Automatic
Transaxle
Road Test
A road test is carried out to assess the problem accurately and to test the
Instructor Guide confidence after servicing.
2. Drive the vehicle to check that the shift points follow the shift diagram.
3. Check shift shock or noise
Note:
• In carrying out the road test, pay attention to the traffic situation and
keep safety in mind.
• Because the shift diagram represents the shifting start speed, Speed at
the end of shifting could differ 2-8 km/h from the diagram.
P Range Test

1. Park the vehicle on an upward slope. (with more than 5° gradient) and
select “P” range. Release the parking brake to check if the vehicle does
not move.
2. Under the same condition, check if the vehicle moves when the selector
lever is moved from “P” range to the other ranges.
3. Similarly, carry out the test on a downward slope.
rev 02
AT Fluid Replacement 3-73
M-Car:
1. Remove the drain plug and drain the AT fluid with the engine stopped
Automatic
and measure the drained oil.
Transaxle
Note : The fluid can not be drained completely.
Instructor Guide
2. Tighten the drain plug with the specified torque.
Tightening torque : 44 Nm (430 kgfcm)
3. Refill the specified fluid through the filler tube the same amount as
drained.
Specified AT fluid : ESSO JWS3314
Total fluid volume : 4.4L
Note : Do not mix with different kind of oil.
Just in case, it may cause problems to the clutches and brakes.
4. Start the engine and idle the engine for at least five minutes.
5. Lift up the vehicle.
6. Gradually elevate the engine speed till approximately 50 km/h in the “D”
range and depress the brake pedal to idle the engine.
Shift to “R” range and release the brake for about 10 seconds and
depress the brake again to idle the engine. Repeat this step two
or three times more.
7. Repeat the above procedure 1 through 5 two times more.
8. For the last, Check the AT fluid level.
Note: The fluid level check must be performed in the engine idling and
the transmission warmed-up.
rev 02
3-74 Precautions
M-Car:
Automatic
Transaxle
When driving and handling the vehicle
Instructor Guide Maintenance Owner’s
No Precautions
manual manual
If the vehicle breaks down, raise the front wheels off the
1
ground and tow the vehicle. If the vehicle is to be towed using
a rope, the towing speed should not exceed 35 km/h and the
{
towing should be completed within an hour.
If the interior of the automatic transmission is damaged, it

2
may cause foreign material to enter the oil cooler and may
cause clogging. If necessary, clean and/or replace the oil
{
cooler.
Be sure to use only specified ATF, ESSO – JWS3314.

3 Different type of ATF may cause problems with the clutch and { {
brake.
When the vehicle is stationary with the brake applied and the
"D", "2", "L" or "R" range is selected, continuing the high-
4 speed rotation of the engine (stall test operation) will cause {
overheating. Do not allow this to continue for more than 5
seconds.
If the AT fluid temperature is less than 20°C, shifting-up to 4th

gear and lock-up operation are not possible. These, however,
5 are not a problem. (It allows the interior of the automatic { {
transmission to be protected.) When the AT fluid temperature
exceeds 20°C, normal gear shifting is possible.
6
"P" should be selected when the vehicle has been brought to
a complete stop.
{ {
Shifting from forward ranges ("D", "2", or "L") to reverse ("R")
7 and vice versa should only happen when the vehicle has { {
been brought to a complete standstill.
If the engine is turning over at high speed when "N" or "P" is

8
selected, do not select another range.(This may cause the
vehicle to start suddenly and may cause damage to the
{ {
interior of the automatic transmission.)
While driving the vehicle, do not drive continuously with the

9
"N" range is selected or do not repeat the shift operation to
"N" range. (The interior of the automatic transmission may be
{ {
damaged.)
rev 02
Precautions 3-75
M-Car:
Automatic
When diagnosing and servicing AT Transaxle
1. When electronic problems are suspected for shifting malfunction. Instructor Guide
: Other than authentic parts or after-sales parts could sometimes
cause problems such as
- TCM malfunction by voltage drop by TV, Stereo sets and so on.
- TCM malfunction by electro-magnetic noise from low resistance high
tension cable.
2. Abnormal shifting point and Shifting shock
: Throttle position sensor could be a cause.
Throttle sensor with long mileage is worn out and its linearity is
degraded.
3. ATF replacement
- Non-authentic ATF can cause clutch capacity shortage, as a result,
shifting shock and slip in shifting.
- In case of water mixing with oil, ATF color becomes milk white.
You should replace AT TM
- If ATF color changes or air bubble is generated because of minor
water mixing or long mileage (0.1 million km), you should replace
ATF.
But, if ATF is polluted badly or you can smell burnt inside, you should
dismantle the AT and repair it.
4. If oil level is too high, abnormal heat generation and oil pressure drop
can cause clutches burn by resistance in operation.
5. Even in case of AT internal damage or breakage, Torque converter
circuit is protected by oil strainer, so you can re-use T/C after cleaning
it.
But, if you can confirm T/C is damaged, then replace it.
rev 02
3-76 Precautions
M-Car:
Automatic
Transaxle
Repairing Torque Converter
Instructor Guide : You can not re-use T/C in case of the follows.
- ATF color changes milk white because of water intrusion inside
AT with lock-up function
- Lock-up clutch malfunction
- Internal breakage by T/C damage
* Inspecting and Cleaning
1. After removing T/C from TM, inspect T/C surface
2. After draining ATF from T/C, inspect the following.
- In case that steel or foreign material is shown inside T/C, replace T/C
- In other cases, go to the third step and clean T/C
- As long as extremely much steel dust is not shown, it is not a matter.
3. Cleaning T/C inside
- ATF drain
- Put ATF 0.5L in T/C and clean T/C by swing T/C left and right.
- Drain ATF
- Repeat the above three steps three times.
rev 02
Disassembling Inspection 3-77
M-Car:
Automatic
Item Inspection Measures Transaxle
- Scratches and Burrs - Replace
Casting parts Instructor Guide
- Clogged oil passages - Passing through with wire or air
and Machining
- Gasket remnant - Remove the gasket remnant.
parts
- Cracked parts - Replace
- Not turning smoothly
- Replace
Bearings - Streaks, pitching, scratches,
- Replace
cracks
Bush and Thrust - Scratches, burrs, wears,
- Replace
washer scorch
- Scratches or Hardened
- Replace
Oil seal and - Circuferential wear
- Replace
Gasket - Piston seal ring, Oil seal,
- Replace
Gasket
- Scratches or Burrs - Replace
Gear
- Teeth considerably worn - Replace
Spline - Burrs, Scratches, Distortion - Replace
Snap ring - Wear, Scratches, Deformation - Replace
Screws - Burrs or Damaged parts - Replace
Spring - Sinking, scorching - Replace
- Wear, Scorching, Plate warp
Clutch disk and
- Clutch distortion, damaged - Replace
Brake disk
spline
Clutch plate and - Wear, Scorch, Deformation

- Replace
Brake plate - Damaged spline
Seal face
- Scratches, Dry spots, wear - Replace
(Lip- contacting
- Clogged with foreign material - Repair
face)
rev 02
3-78 Valve body Maintenance
M-Car:
Automatic
Transaxle
Instructor Guide
1. Shift Solenoid A
2. Shift Solenoid B
3. Line Pressure Solenoid
4. ATF Temperature Sensor
5. Lock-up Solenoid
6. Oil Strainer
Dismantling
1. Remove the battery terminal
2. Remove the drainage plug to drain the AT fluid.
3. Remove the oil pan.
4. Remove the connector from the solenoid.
5. Remove the ATF temperature sensor fixing bolts.
6. Remove the strainer.
7. Remove the valve body assembly and the shift solenoid.
Note: Since AT fluid can’t be drained through the drain hole thoroughly, put a
vessel under the transmission when removing the oil pan.
Tightening torque
- Shift solenoid bolt 8 N - m {80 kgf - cm}
- Valve body installation bolt 8 N - m {80 kgf - cm}
- Strainer installation bolt 8 N - m {80 kgf - cm}
- Drainage plug 44 N - m {430 kgf - cm}
rev 02
Bearing 3-79
M-Car:
Automatic
Transaxle
Instructor Guide
* Legend
A. Race built-in bearing
B. One-side race needle bearing (Side cover direction)
B’. One-side race needle bearing (Engine side direction)
C. One-side race needle bearing + Race
1. Low & Reverse Brake

2. Low Clutch
3. Internal Gear
4. Rear Carrier
5. Rear Sun Gear
6. Front Carrier
7. One-way Clutch
8. Front Sun Gear Ass’y
9. High Clutch Hub
10. High Clutch
11. Reverse Clutch
rev 02
Servo Release
Servo Apply Cooler Outlet
Cooler Inlet =
Low Clutch Centrifugal Torgue Converter Outlet
Oil Pressure Cancel &
Bearing LUB.
Line P
Check
Cooler Inlet Reverse Clutch
T/C REL O/P OUT High Clutch
T/C APP
Oil Pump Inlet
Oil Pressure Circuit
L&R/B
Low Clutch
Servo Apply
Case
Servo Release High Clutch Reverse Clutch

M-Car:
Automatic
Transaxle
Instructor Guide
3-80
rev 02
Oil Pressure Circuit 3-81
M-Car:
Automatic
Side Cover and Oil Pump Transaxle
Instructor Guide
High Clutch
Reverse Clutch
Cooler Outlet
Cooler Inlet
Oil Pump Outlet Torque Converter Outlet
Torque Converter Release = Cooler Inlet
Torque Converter Apply
Oil Pump Inlet

Low Clutch Centrifugal Oil Pressure
Cancel & Bearing Lubrication
rev 02
3-82 Oil Pressure Circuit
M-Car:
Automatic
Transaxle
Valve Body
Instructor Guide
Line Pressure Duty Solenoid
Shift Solenoid B
Shift Solenoid A
Lock-up Duty Solenoid
T/C Release T/C Apply

Oil Pump Outlet
Oil Pump Inlet
Lower Clutch
Low & Reverse Brake
Cooler Inlet
High Clutch
Servo Apply
Servo Release
Reverse Clutch
rev 02
Symptom Troubleshooting 3-83
M-Car:
Symptom Troubleshooting Chart Automatic
Transaxle
Onboard check Dis as s embly check
P robable caus e E lectrical s ys tem
Instructor Guide
Oil P owerflow s ys tem
E xternal AT X Internal AT X pres s ure
T rouble s ymptoms
Vehicle will not move in an

Vehicle will not move in " D"
Vehicle will not move in " D" ,
Vehicle will not move in " R " .
Vehicle moves in " N" .
Lower than normal
maximum s peed
and/or poor
acceleration
No s hift in any range

No 1-2 s hift-up
No 2-3 s hift-up
No 3-4 s hift-up
S hift point is high or low.
Lock-up does not operate.
Clutch s lips when

vehicle s tarts
(in forward ranges ).
Clutch s lips when
vehicle s tarts
(in the revers e range).
Clutch s lips in 1-2 s hift-up.
No engine braking in L.
H ars h s hock in 1-2 s hift-up.

H ars h s hock during
driving when
s elector is moved from
" N" to " D" .
H ars h s hock during
driving when
s elector is moved from
" N" to " R " .
Nois e when idling

Nois e when s elector is m
Nois e when driving
Nois e when s hifting
E ngine s talls .
Oil blows out from air breath
S tarter will not rotate in " P
rev 02
3-84 Symptom Troubleshooting
M-Car:
Automatic
1-1 Vehicle will not move in any range.
Transaxle
Probable cause
Instructor Guide - Low line pressure - Error in control valve spool sliding
- Incorrect ATF level adjustment - Damage to gear(s)
- Incorrect select linkage adjustment - Faulty parking release
- Broken or damaged oil pump - Faulty engine system
- Malfunction of torque converter
Step Check Action

Carry out an engine performance check to
ensure that the engine is behaving
normally. Then proceed with the ATX
check.
YES Go to the next step.

Is the ATF level correct when
1
checked during the primary check?
Adjust the ATF level as specified.
NO
*If the ATF is burnt or dirty, replace the ATX.
Is there any slippage in the select YES Go to the next step.

2 linkage when checked during the
primary check? NO Adjust the select linkage.
Check the following: (ATX disassembly)

- Damage to each of the gears
YES (Output gear, idle gear, and differential gear)
- Torque converter
Is the measured line pressure within - Operation of the parking mechanism
3
the specified range?
NO - Damage to or wear of the oil pump
- Operation of the control valve spool
rev 02
1-2 Vehicle will not move in Dor 2 M-Car:
Automatic
Probable cause Transaxle
- Low clutch slip
Instructor Guide
- Low one-way clutch slip
Step Check Action
In the case where the ATF level Check the following: (ATX
and the line pressure measured disassembly)
in the primary check are correct: - Bum or wear of the low clutch
- Operation of the tow one-way
clutch
1-3 Vehicle will not move in D, 2 or L

Probable cause
- Low clutch slip
- Low & reverse clutch slip
Step Check Action
- Bum or wear of the low & reverse
clutch

Probable cause
- Reverse clutch slip
- Low & reverse clutch slip
Step Check Action
- Bum or wear of the low & reverse
clutch

Probable cause
- Sticking of the low clutch resulting form burning or malfunction
Step Check Action
In the case where the select Check the following: (ATX
linkage adjustment checked in disassembly)
the pramary check is corred: - Operation of the low clutch rev 02
M-Car:
Automatic
Transaxle 1-6 Lower than normal maximum speed and/or poor acceleration.
Instructor Guide Probable cause

- Faulty ATCU - Damage to or wear of oil pump
- Faulty O/D switch - Malfunction of torque converter
- Faulty ATF temperature sensor - Error in control valve spool sliding
- Faulty line pressure solenoid - Slip or malfunction of high clutch
- Faulty shift solenoid - Slip or malfunction of 2-4 brake band
Step Check Action

According to the service code check, verify the
following parts:
- O/D switch (No service code)
YES
Has the service code been output - ATF temperature sensor
1 - Line pressure solenoid
during the primary check?
- Shift solenoid
NO Go to step 2.
Is the problem rectified by replacing YES Replace the ATCU.

the ATCU with that of the same
2
vehicle type?
NO Go to step 3.

- Disassemble the oil pump assembly and
check it for damage or wear.
Disassemble the ATX and check the - Check the sliding of the control valve spool.
3
interior. - Check operation of the high clutch and check
the plates for burning.
- Check operation of the 2-4 brake band and
check the band for burning.
4 If no faults are detected in step 3. - Replace the torque converter.
rev 02
M-Car:
2-1, 2-2 No shift in any rage. No 1-2 shift-up.
Automatic
Transaxle
Probable cause
Instructor Guide
- Improper positioning of inhibitor switch - Faulty vehicle speed sensor
- Fault in inhibitor switch itself - Faulty ATCU
- Malfunction of shift solenoid A - Malfunction of 2-4 brake band
- Malfunction of shift solenoid B - Malfunction of control valve spool
Step Check Action
1 Has the service code been output YES According to the service code check,
during the primary check? verity the following parts:
- Shift solenoid A
- Shift solenoid B
- Vehicle Speed sensor
- Positioning of inhibitor switch and short or
open circuit inside the switch.
NO Go to step 2.
2 Is the problem rectified by YES Replace the ATCU.

replacing the ATC11 with that of
the same vehicle type? NO Go to step 3.
3 Is the line pressure measured YES Check the following: (ATX disassembly)
during the primary check within - Operation of the 2-4 brake band
the specified range? NO Check the following: (ATX disassembly)
2-3 No 2-3 shift-up.
Probable cause
- Improper positioning of inhibitor switch - Malfunction of high clutch
- Fault in inhibitor switch itself - Malfunction of control valve spool
- Malfunction of shift solenoid B
Step Check Action
1 Has the service code been According to the service code check,
output short or during the verify the following parts:
primary check? YES - Shift solenoid B
- Positioning of the inhibitor switch and
open circuit inside the switch.
NO Go to step 2.
2 Is the check within the specified YES Cheek the following: (ATX disassembly)
primary range? Is the line pressure measured during
- Operation of the high clutch
NO Check the following: (ATX disassembly)
rev 02
M-Car:
Automatic 2-4 No 3-4 shift-up
Transaxle
Probable cause
Instructor Guide
- Fault in inhibitor switch itself - Faulty ATF temperature sensor
- Malfunction of shift solenoid A - Faulty ATCU
- Malfunction of shift solenoid B - Malfunction of control valve spool
- Faulty O/D switch
Step Check Action
1 Has the service code been output According to the service code check,
ATF temperature sensor during verify the following parts:
the primary check? - Shift solenoid A
YES - Shift solenoid B
- O/D switch (No service code)
- Short or open circuit inside inhibitor
switch
NO Go to step 2.
2 Is the problem rectified by YES Replace the ATCU.

replacing the ATCU with that of
the same vehicle type? NO Check the following: (ATX disassembly)
2-5 Shift points is high or low.
Probable cause
- Error in throttle position sensor
- Faulty vehicle speed sensor
- Malfunction of control valve spool
Step Check Action
during the primary check? YES verity the following parts:
- Vehicle speed sensor
NO Go to step 2.
2 In response to the throttle YES Check the following: (ATX disassembly)

opening angle is the throttle - Operation of the control valve spool
voltage of the throttle position NO Adjust the mounting angle of the throttle
sensor within the cheek? position specified range in the primary
sensor.
rev 02
M-Car:
Automatic
2-6 Lock-up does not operate.
Transaxle
Probable cause
- Faulty ATCU - Faulty speed sensor Instructor Guide
- Fault in inhibitor switch itself - Faulty ATF temperature sensor
- Engine speed sensor - Malfunction of control valve spool
- Faulty turbine sensor - Malfunction of torque converter
- Malfunction of lock-up solenoid
Step Check Action

According to service code check, verify the
following parts:
- Lock-up solenoid
- Engine speed sensor
YES
1 - Vehicle speed sensor
- Turbine sensor
- Short or open circuit inside inhibitor switch
NO Go to step 2.
Is the problem rectified by YES Replace the ATCU.

2 replacing the ATCU with that of
the same vehicle type? Check the following: (ATX disassembly)
NO
In the case where no faults are

3 - Replace the torque converter.
detected in steps 1 and 2.
rev 02
M-Car:
Automatic
3-1 Clutch slips when vehicle starts (in forward ranges).
Transaxle
Probable cause
Instructor Guide - Low line pressure - Malfunction of line pressure solenoid
- Incorrect adjustment of select - Malfunction of low clutch
linkage - Malfunction of low one-way clutch
- Error in throttle position sensor - Malfunction of control valve spool
- ATF level out of specification
Step Check Action

Carry out an engine performance
check to ensure that the engine is
behaving normally. Then proceed with
the ATX check.
According to the service code check, verify
YES the following parts:
Has the service code been output - Line pressure solenoid
1
NO Go to step 2.
YES Go to step 3.
2 checked during the primary Adjust the ATF level as specified.
check? NO *If the ATF is burnt or dirty, replace the
ATX.
Were any faults detected in the YES Check and adjust the select linkage.
3 select linkage during the primary
check? NO Go to step 4.
In response to the throttle opening Adjust the mounting angle of the throttle
angle is the throttle voltage of the YES
position sensor.
4 throttle position sensor within the
specified range in the primary NO Go to step 5.
check?
Is the line pressure measured YES - Operation of the low clutch
5 during the primary check within - Operation of the low one-way clutch
the specified range? Check the following: (ATX disassembly)
NO
rev 02
M-Car:
Automatic
3-2 Clutch slips when vehicle starts (in the reverse range).
Transaxle
Probable cause
- Low line pressure - Malfunction of line pressure solenoid Instructor Guide
- Incorrect adjustment of select - Malfunction of low & reverse clutch
linkage - Malfunction of reverse clutch
Step Check Action

the ATX check.
1
NO Go to step 2.
YES Go to step 3.
ATX.
position sensor.
check?
Is the line pressure measured YES - Operation of the low & reverse clutch
5 during the primary check within - Operation of the reverse clutch
NO
rev 02
M-Car:
Automatic
3-3 Clutch slips in 1-2 shift-up
Transaxle
Probable cause
linkage - Malfunction of 2-4 brake band
Step Check Action

the ATX check.
1
NO Go to step 2.
Is the ATF level correct when YES Go to step 3.

checked during the primary
2 Adjust the ATF level as specified.
check?
NO *If the ATF is burnt or dirty, replace the
ATX.
position sensor.
check?
5 during the primary check within - Operation of the 2-4 brake band
NO
rev 02
M-Car:
Automatic
3-4 Clutch slips in 2-3 shift-up
Transaxle
Probable cause
- Low line pressure - Malfunction of line pressure solenoid Instructor Guide
linkage - Malfunction of high clutch
Step Check Action

the ATX check.
1
NO Go to step 2.
YES Go to step 3.
ATX.
position sensor.
check?
Is the line pressure measured in YES - Operation of the low clutch
5 the primary check within the - Operation of the high clutch
specified range? Check the following: (ATX disassembly)
NO
rev 02
M-Car:
Automatic
3-5 Clutch slips in 3-4 shift
Transaxle
Probable cause
- Incorrect adjustment of select - Malfunction of high clutch
linkage - Malfunction of 2-4 brake band
Step Check Action

the ATX check.
1
NO Go to step 2.
YES Go to step 3.
ATX.
position sensor.
check?
YES - Operation of the high clutch
Is the line pressure measured - Operation of the 2-4 brake band
5 during the primary check within
the specified range? NO
rev 02
M-Car:
Automatic
3-6 No engine braking in “L”.
Transaxle
Probable cause
- Low line pressure - Malfunction of shift solenoid A Instructor Guide
- ATF level out of specification - Malfunction of shift solenoid B
linkage - Malfunction of low & reverse clutch
- Incorrect positioning of inhibitor - Malfunction of control valve spool
switch
- Faulty ATCU
Step Check Action
the ATX check.
the following parts:
YES - Shift solenoid A
Has the service code been output - Shift solenoid B
1
during the primary check? - Positioning of the inhibitor switch
NO Go to step 2.
YES Go to step 3.
2 Adjust the ATF level as specified.
checked in the primary check?
NO *If the ATF is burnt or dirty, replace the
ATX.
Is the problem rectified by YES Replace the ATCU.

4 replacing the ATCU with that of
the same vehicle type? NO Go to step 5.

5 during the primary check within - Operation of the low & reverse clutch
NO
rev 02
M-Car:
Automatic
4-1 Harsh shock in 1-2 shift-up
Transaxle
Probable cause
Instructor Guide - Low or high line pressure (shifting - Malfunction of line pressure solenoid
out of specification) - Error in control valve spool sliding
- Error in throttle position sensor - Malfunction of 1-2 accumulator
- Incorrect adjustment of 2-4 brake - Faulty ATCU
band
- Breakage of or damage to oil pump
- Faulty ATF temperature sensor
Step Check Action
YES - ATF temperature sensor
1
during the primary check? - Throttle position sensor
NO Go to step 2.
In response to the throttle opening
angle is the throttle voltage of the YES Go to step 3.
throttle position sensor within the
2
specified range in the primary Adjust the mounting angle of the throttle
check? NO
position sensor.
Check whether the problem is rectified by

replacing the ATCU with that of the same
vehicle type.
3 Check the ATCU itself.
- If the problem is rectified, replace the
ATCU.
- If not, go to step 4.
YES - Return at the 2-4 brake band adjustment
Is the line pressure measured - Operation of the 1-2 accumulator
rev 02
M-Car:
Automatic
Transaxle
Probable cause
- Low or high line pressure (shifting - Malfunction of line pressure solenoid Instructor Guide
- Error in throttle position sensor - Malfunction of servo release accumulator
- Malfunction of high clutch - Faulty ATCU
- Breakage of or damage to oil pump - No steel ball in control valve
Step Check Action
1
NO Go to step 2.
NO
check? position sensor.
vehicle type.
ATCU.
- Operation of the high clutch
YES
- Operation of the servo release
Is the line pressure measured accumulator
the specified range?
- Damage or wear of the oil pump
NO
- No steel ball in the control valve
rev 02
M-Car:
Automatic
Transaxle
Probable cause
Instructor Guide - Low or high line pressure (shifting - Malfunction of line pressure solenoid
- Error in throttle position sensor - Malfunction of servo release accumulator
- Malfunction of 2-4 brake band - Faulty ATCU
Step Check Action
the following parts.
1
NO Go to step 2.
NO
check? position sensor.
vehicle type.
ATCU.
- Return of the 2-4 brake band after
YES adjustment
Is the line pressure measured - Operation of the servo release
4 during the primary check within accumulator
the specification?
rev 02
M-Car:
Automatic
4-4 Harsh shock during driving when selector is moved from “N” to “D” range Transaxle
Probable cause
- Low or high line pressure (shifting - Malfunction of line pressure solenoid
Instructor Guide
- Improper positioning of inhibitor - Malfunction of low clutch accumulator
switch - Faulty ATCU
- Malfunction of low clustch - Faulty engine system
Step Check Action
the ATX check.
YES
NO Go to step 2.
YES Go to step 3.
Is the inhibitor switch positioned
2
properly?
NO Adjust the positioning of the inhibitor switch.
vehicle type.
3 Check the ATCU itself
ATCU.
YES - Operation of the low clutch
Is the line pressure measured - Operation of the low clutch accumulator
rev 02
M-Car:
Automatic
Transaxle 4-5 Harsh shock during driving when selector is moved from “N” to “R” range
Instructor Guide Probable cause

- High line pressure - Malfunction of line pressure solenoid
- Incorrect positioning of inhibitor - No steel ball in control valve
switch - Malfunction of low & reverse clutch
- Malfunction of reverse clutch - Faulty ATCU
- Breakage of or damage to oil pump - Faulty engine system
Step Check Action
the ATX check.
YES
NO Go to step 2.
YES Go to step 3.
Is the inhibitor switch positioned
2
properly?
NO Adjust the positioning of the inhibitor switch.
vehicle type.
ATCU.
YES - Operation of the reverse clutch
Is the line pressure measured - Operation of the low & reverse clutch
- No steel ball in the control valve
rev 02
M-Car:
5-1 Noise when idling
Automatic
Transaxle
Probable cause
Instructor Guide
- Pump noise caused by trouble in oil circuit or oil control system
- Noise from engine auxiliaries
Step Check Action
1 Does the tone change according Check the following: (Visual inspection,
to the engine speed? ATX disassembly)
And, does the noise level increase YES - Dent in the oil pan
when the line pressure is - Cloggin up in the strainer
maximized in intentional fail safe - Error in the oil pump rotor
mode? NO Check the following: (ATX disassembly)
- Error in the engine auxiliaries
5-2 Noise when selector is moved
Probable cause
- Faufty low clutch (N_>D)
- Faulty reverse clutch (N__)R)
- Faulty low & reverse brake (N_>R)
Step Check Action
Is the line pressure measured Check the following: (ATX disassembly)

during the primary check within - Low clutch assembly
the specified range? YES - Bum or wear of the low clutch
- Reverse clutch assembly
- Bum or wear of the reverse clutch
NO - Operation of the control valve spool
- Damage to or wear of the oil pump
rev 02
M-Car:
Automatic 5-3 Noise when vehicle is moving
Transaxle
Probable cause
Instructor Guide
- Planetary gear noise - Oil pump noise
- Output gear noise - Torque converter noise
- Final gear noise - Noise from engine auxiliary
- Low one-way clutch sliding noise - Noise from vehicle drive shaft
- Bearing noise - Noise from vehicle wheel bearing
Step Check Action
1 Does the tone change according Check the following: (Visual inspection,
to the engine speed? ATX disassembly)
And, does the noise level increase - Dent in the oil pan
when the line pressure is YES - Clogging up in the strainer
maximised in intentional fail safe - Error in the oil pump rotor
mode? - Torque converter
No Go to step 2.
2 Does the noise occur in a specific Check the following: (ATX disassembly)
range other than in 3rd gear? YES - Damage or abnormal wear of the
Also, does the tone change planetary gear
according to vehicle speed? NO Go to step 3.
3 Does the noise occur in all Check the following: (ATX disassembly)
ranges? - Damage or abnormal wear of output and
Also, does the tone change final gears
according to vehicle speed? - Flaw or abnormal wear of the low one-
way clutch
YES - Flaw or abnormal wear of each bearing
- Rattle or abnormality in the vehicle drive
shaft
- Abnormal wear or flaws in the vehicle
wheel bearing
- Errors related to engine auxiliary
5-4 Noise when shifting
Probable cause
- Clutch slip or error when shifting
- Planetary gear noise when shifting
- C1V operation noise when shifting
Step Check Action
1 Is the line pressure measured Check the following: (ATX disassembly)

during the primary check within YES - Clutches related to shifting
the specified range? - Damage to or abnormal wear of the
planetary gear
rev 02
M-Car:
6-1 Engine stalls
Automatic
Transaxle
Probable cause
Instructor Guide
- Incorrect ATF level adjustment - Error in control valve spool sliding
- Line pressure out of specification - Malfunction of torque converter
- Malfunction of line pressure solenoid - Faulty engine system
- Malfunction of lock-up solenoid
Step Check Action

check to ensure that the engine
is behaving normally. Then
proceed with the ATX check.
during the primary check? verify the following parts:
YES - Line pressure solenoid
- Lock-up solenoid
NO Go to step 2.
2 Is the ATF level correct when YES Go to step 3.

checked during the primary NO Adjust the ATF level as specified.
check? *if the ATF is burnt or dirty, replace the
ATX.
3 Is the line pressure measured YES Go to step 4.

during the primary check within Check the following: (ATX disassembly)
the specified range? NO - Damage to or wear of the oil pump
4 Replace the torque converter.
6-2 Oil blows out from air breather.
Probable cause
- Too much ATIF
Step Check Action
1 Check and adjust the ATF level.
rev 02
M-Car:
Automatic
6-3 Starter will not rotate in “P” and/or “N”.
Transaxle
Probable cause
Instructor Guide - Improper adjustment of select - Improper positioning of inhibitor switch
linkage - Faulty ATCU
- Faulty engine system
Step Check Action

the ATX check.
Following the inhibitor switch inspection,
YES check and adjust the positioning of the
Is the inhibitor switch positioned inhibitor switch.
2
properly?
NO Go to step 3.

3 - Damage to or wear of the oil pump
rev 02
Special Tool 3-105
M-Car:
Automatic
Transaxle
Instructor Guide
Valve Lifter Attatchment Valve Lifter
Low Clutch Spring Compressor Reverse Clutch Spring Compressor
Low&Reverse Brake Spring Compressor High Clutch Spring Compressor
rev 02
3-106 Special Tools
M-Car:
Automatic
Transaxle
Instructor Guide Low One Way Clutch Installer Spring Pin Remover
Spring Pin Installer Output Gear Holder
Output Gear Locknut Remover/Installer Input Shaft Oil Seal Installer
rev 02
Special Tools 3-107
M-Car:
Automatic
Transaxle
Differential Side Oil Seal Installer (Oil Pan Side) Differential Front Side Oil Seal Installer Instructor Guide
Transaxle Remove/Install Support
rev 02
3-108
M-Car:
Automatic
Transaxle
Instructor Guide
rev 02
CAPÍTULO 4
CAJA DE CAMBIOS MANUAL
Embrague y caja de cambios manual: Especificaciones........................... 5

Embrague.................................................................................................. 6
Embrague: herramientas especiales......................................................... 7
Partes del tren delantero........................................................................... 8
Caja de cambios manual........................................................................... 9
Caja de cambios: control de cambios...................................................... 11
Caja de cambios: Tren de engranajes..................................................... 13
Caja de cambios: diferencial.................................................................... 14
Caja de cambios: mantenimiento............................................................. 15
Caja de cambios: cable de control del engranaje de cambios................. 17
Caja de cambios: herramientas especiales.............................................. 19
M-Car:
Manual
Clutch and Manual Transaxle: Specifications ............................................ 5 Drivetrain
Clutch ........................................................................................................ 6
Instructor Guide
Clutch: Special Tools ................................................................................. 7
Drive Shaft Parts ....................................................................................... 8
Manual Transaxle ...................................................................................... 9
Manual Transaxle: Shift Control ............................................................... 11
Manual Transaxle: Gear Train .................................................................. 13
Manual Transaxle: Differential ................................................................. 14
Manual Transaxle: Maintenance .............................................................. 15
Manual Transaxle: Gear Shift Control Cable ............................................ 17
Manual Transaxle: Special Tools ............................................................. 19
Manual Drivetrain: Lab 1 ......................................................................... 20
Manual Drivetrain: Test Questions ........................................................... 21
MD-1
rev 02
4-4
M-Car:
Manual Drivetrain
Instructor Guide
rev 02
Clutch and Manual Transaxle: Specifications 4-5
M-Car:
Manual
Clutch Drivetrain
Type Single Dry Plate
Outside Diameter 170 mm (6.7 in)
Inside Diameter 110 mm (4.3 in)
Thickness 7.15 mm (0.300 in)
Manual Transaxle
Maker DWMC
Forward : Synchronized mesh

Type or Model
Reverse : Sliding mesh
Gear ratio
1st 3,818
2nd 2,21
3rd 1,423
4th 1,029
5th 0,837
Reverse 3,583
Final gear ratio 4,444

Oil capacity (L) 2.1 L (2.2 qts)
rev 02
4-6 Clutch
M-Car:
Manual Drivetrain
Instructor Guide
Disc type Single Dry Plate
Outside diameter 170mm (7 in)

MD-2 Clutch Disc
Inside diameter 110mm (4 in)
Thickness 7.15mm (.28 in)

100 - 110mm (3.9 - 4.3
Pedal Travel (A)
in)
Clearance between pedal and Floor just before
30 - 40mm (1.2 - 1.6 in)
clutch engagement (B)
rev 02
Clutch: Special Tools 4-7
M-Car:
Manual
Drivetrain
09917-58010 Instructor Guide
09930-30102
Brake Spring
Sliding Shaft
Bearing Remover
09923-46040 09943-88211
Bushing Joint Bushing, Bearing
Pipe Installer
09924-17810 DW110-021
Fly Wheel Holder Engine Assembly
Support Fixture
MD-3
09925-48220 DW210-010
Bushing Clutch Center
Remover/Installer Guide
09925-98210
Input Shaft
Bearing Installer
rev 02
4-8 Drive Shaft Parts
M-Car:
Manual Drivetrain
Instructor Guide
1. Outer joint (Rzeppa) 6. Inner small boot clamp

2. Outer large boot clamp 7. Inner boot
3. Outer boot 8. Inner large boot clamp
4. Outer small boot clamp 9. Inner joint (Tripot)
5. Drive axle shaft 10. Inner joint housing
MD-4
rev 02
Manual Transaxle 4-9
M-Car:
Manual
Drivetrain
Instructor Guide
Description of Manual Transaxle

This five–speed transaxle assembly adopts the synchronized mesh type of
5 forward speed. The reverse speed gear is driven by sliding idle gear
without synchronizer.
MD-5
Specifications
Application 0.8L SOHC 1.0L SOHC Remarks
Model Y3S Y4M
Maker DWMC DWMC
1st 3,818 3,417
2nd 2,21 1,95
3rd 1,423 1,28

Gear ratio
4th 1,029 0,914
5th 0,837 0,758
REV 3,583 3,273
Final drive W/Europe 4,444 4,444

ratio
General Area 4,444 4,444
SAE 75W-85
Oil capcity (L) 2.1L(2.22qt) 2.1L(2.22qt)
(GL-4)
Inspect : Every 15,000KM or 12 months
Maintenance interval
Exchange: Every 30,000KM or 24 months rev 02
4-10 Manual Transaxle
M-Car:
Manual Drivetrain
Reverse Gear Miss Shift Preventing Mechanism
The 5th and reverse gear cam prevents the gear from directly being shifted
Instructor Guide from 5th to reverse when shifting to reverse from 5th. So, when shifting to
reverse, be sure to shift to reverse from neutral position and reverse, gear
shift and select lever arm rotates to left and shifting is possible.
When shifting to reverse from 5th gear, shifting to reverse is impossible
because 5th and reverse gear shift cam fixs on cam stopper’ case.
When shifting to reverse from neutral position between 5th and reverse,
gear shift and select lever arm rotates to left and shifting is possible.
MD-6
rev 02
Manual Transaxle: Shift Control 4-11
M-Car:
Manual
Drivetrain
Instructor Guide
MD-7
1. Gear Shift Control Lever Knob 5. Select Arm

2. Gear Shift Cable Bracket 6. Gear Shift Control Lever
3. Select Cable 7. Gear Shift Control Lever Guide
4. Shift Cable
rev 02
4-12 Manual Transaxle
M-Car:
Manual Drivetrain
Instructor Guide
1. Speedometer Driven Gear 14. Differential Oil Seal(Left)

MD-8 2. Oil Level Plug 15. Differential Bearing(Left)
3. Case Cap O-ring(Left) 16. Differential Case
4. Case Cap(Left) 17. Speedometer Drive Gear
5. Reverse Light Switch 18. Differential Bearing(Right)
6. Transaxle Case(Right) 19. Differential Oil Seal(Right)
7. Oil Plate 20. Differential Pinion Gear Shaft Pin
8. Transaxle Case(Left) 21. Differential Side Gear Adjust Shim
9. Oil Drain Plug 22. Differential Side Gear
10. Oil Gutter 23. Differential Pinion Gear Shaft
11. Side Cover Plate 24. Differential Pinion Gear
12. Side Cover 25 . Differential Pinion Gear Washer
13. Differential Ring Gear
rev 02
Manual Transaxle: Gear Train 4-13
M-Car:
Manual
Drivetrain
Instructor Guide
1. Input Shaft Circlip 25. Input Shaft Oil Seal

2. 5th Gear Synchronizer Plate 26. Reverse Gear Shaft Bolt
3. 5th Gear Synchronizer Sleeve 27. Reverse Gear Shaft MD-9
4. 5th Gear Synchronizer Spring 28. Reverse Idle Gear
5. 5th Gear Synchronizer Key 29. Counter Shaft Nut
6. 5th Gear Synchronizer Hub 30. Counter Shaft 5th Gear
7. 5th Gear Synchronizer Ring 31. Counter Shaft Bearing Shim
7a. Wave Spring 32. Counter Shaft Bearing(Left)
8. Input Shaft 5th Gear 33. Counter Shaft 4th Gear
9. Input Shaft 5th Gear Bearing 34. Counter Shaft 3rd-4th Gear Spacer
10. Input Shaft 5th Gear Spacer 35. Counter Shaft 3rd Gear
11. Input Shaft Bearing(Left) 36. Counter Shaft 2nd Gear
12. Input Shaft 4th Gear 37. 2nd Gear Synchronizer Ring
13. 4th Gear Synchronizer Ring 38. Counter Shaft 2nd Gear Bearing
14. Wave Spring 39. 1st-2nd Gear Synchronizer Circlip
15. Input Shaft 4th Gear Bearing 40. 1st-2nd Gear Synchronizer Sleeve
16. 3rd-4th Gear Synchronizer Sleeve 41. 1st-2nd Gear Synchronizer Spring
17. 3rd-4th Gear Synchronizer Spring 42. 1st-2nd Gear Synchronizer Key
18. 3rd-4th Gear Synchronizer Key 43. 1st-2nd Gear Synchronizer Hub
19. 3rd-4th Gear Synchronizer Hub 44. 1st Gear Synchronizer Ring
20. 3rd-4th Gear Synchronizer Ring 45. Counter Shaft 1st Gear
21. 3rd-4th Gear 46. Counter Shaft 1st Gear Bearing
22. 3rd-4th gear Bearing 47. Counter Shaft
23. Input Shaft 48. Counter Shaft Bearing(Right)
24. Input Shaft Bearing rev 02
4-14 Manual Transaxle: Differential
M-Car:
Manual Drivetrain
Instructor Guide
MD-10
1. Differential Case 8. Differential Ring Gear Bolt

2. Differential Ring Gear 9. Differential Pinion Gear Shaft
3. Differential Bearing 10. Differential Pinion Gear
4. Differential Oil Seal 11. Differential Side Gear
5. Speedometer Driven Gear 12. Differential Pinion Gear Washer
6. Differential Pinion Gear 13. Differential Side Gear
Shaft Pin Adjustment Shim
7. Differential Oil Seal
rev 02
Manual Transaxle: Maintenance 4-15
M-Car:
Manual
Drivetrain
Instructor Guide
1. Drain Plug 2. Oil Level Plug
Check for leaks in the transaxle case seals, then check fluid level and MD-11
condition of fluid after removing fluid level plug.
1. Operate the engine until it comes to normal operating temperature
(Coolant temperature: 80 - 90°C / 176-195°F).
2. Turn engine off and raise the vehicle.
3. Remove the fluid level plug and check the fluid level.
4. The fluid should slightly flow out from the oil level plug hole.
5. If the level is low, add the recommended fluid through the oil level plug
hole until the fluid begins to run out.
6. If the fluid is contaminated or discolored, replace it with the
recommended fluid. (See Service Manual for recommended fluid.)
7. Reinstall the oil level plug and tighten it securely.
rev 02
4-16 Manual Transaxle: Maintenance
M-Car:
Manual Drivetrain
Changing Fluid
Many noises that seem to come from the transaxle may actually originate with
Instructor Guide other sources such as tires, road surfaces, wheel bearings, engine or
exhaust system. Identify the cause of any noise before attempting to repair
the clutch, transaxle or related linkages.
To verify the cause of any noise
1. Select a smooth, level asphalt road to reduce tire and resonant body
noise.
2. Drive the vehicle far enough to warm up all the lubricants thoroughly.
3. Record the speed and the gear range of the transaxle when the noise
occurs.
4. Check for noises with the vehicle stopped and the engine running
5. Determine if the noise occurs while the vehicle operates in:
• Drive - under a light acceleration or a heavy pull
• Cruise - maintaining a constant speed with a light throttle on a level
road
• Coast - transaxle in gear and the throttle partly or fully closed
• All of the above
Differential Side Bearing Noise

Differential side bearing noise and wheel bearing noise can be confused
easily. Since side bearings are preloaded, a differential side bearing noise
should not diminish much when the differential / transaxle is run with the
wheels off the ground
Wheel Bearing Noise

Wheel bearings produce a rough growl or grating sound that will continue
when the vehicle is coasting and the transaxle is in NEUTRAL. Since wheel
bearings are not pre-loaded, a wheel bearing noise should diminish
considerably when the wheels are off the ground.
rev 02
Manual Transaxle: Gear Shift Control Cable 4-17
M-Car:
Manual
Removal Procedure Drivetrain
1. Remove the air hose (air
cleaner to throttle body) Instructor Guide
2. Remove the battery
3. Disconnect the transaxle side
select and shift control cable.
• Remove the cable pins (1)
• Remove the washers (2)
• Disconnect the select and
shift control cable (3)
• Remove the cable
E-rings (4)
• Disconnect the cables
from the cable bracket
4. Remove the floor console. Pull
the floor carpet aside to
uncover the gear shift cable as
shown
5. Disconnect the gear shift lever
and shift control cable MD-12
• remove the select control
cable clip (5)
• pry off the eye ring (6)
• remove the select control
cable E-ring (7)
• disconnect the select
control cable (8)
• remove the shift control
cable pin (9)
• remove the shift control
cable E-ring (10)
• pry off the shift control
cable (11)
6. Remove the select and shift
control cable
• remove the nuts
• pull the cables into the
passenger compartment
rev 02
4-18 Manual Transaxle: Gear Shift Control Cable
M-Car:
Manual Drivetrain
Installation Procedure
1. Installation is the reverse of
Instructor Guide removal
2. Push the cable toward the
engine compartment
through the hole in the
firewall.
3. Position the cables on the
select and the shift lever.
4. Connect the transaxle side
select and shift control cable
5. Connect the gear shift lever
side shift control cable
6. Connect the gear shift lever
side select control cable
• Insert the select control
cable eye ring to the
select arm pin (1)
• Install the selector lever
control cable clip (2)
MD-13 • Install the select control
cable to gear shift lever
bracket with E-ring (3)
• Insert a driver into the
select arm adjustment
hole to prevent the
movement of gear shift
lever in NEUTRAL (4)
7. Tighten the select cable
adjust nut to 8 – 12 Nm (5-9
lb/ft)
rev 02
Manual Transaxle: Special Tools 4-19
M-Car:
Manual
Drivetrain
DW220-031
DW220-020A-01 Instructor Guide
Transaxle
Differential Remove/Install
Bearing Puller Support
DW220-020A-02
Differential KM466-A
Bearing Plate Gear, Beating
Adapter Remover/Installer
DW220-020A-03
Differential KM519
Bearing Plate Oil Seal Installer
Adapter
MD-14
rev 02
M-Car
Service Training Manual:
Suspension and Steering
Instructor Guide
M-Car:
Suspension
Suspension ............................................................................................... 5 and Steering
Suspension: Front ...................................................................................... 6
Instructor Guide
Suspension: Front ...................................................................................... 7
Suspension: Front Toe Adjustment ............................................................ 8
Suspension: Rear ...................................................................................... 9
Suspension: Wheel Bearing Adjustment ................................................. 10
Suspension: Special Tools ...................................................................... 11
Suspension: Power Steering ................................................................... 13
Power Steering ........................................................................................ 14
Power Steering: Pump ............................................................................. 15
Power Steering: Control Valve Unit .......................................................... 16
Power Steering: Control Valve Operation ................................................ 17
Power Steering: Pressure Switch ............................................................ 18
Power Steering: Steering Column ........................................................... 19
Power Steering: Gear Parts ..................................................................... 20
Power Steering: Rack .............................................................................. 21
Power Steering: Straight Ahead Check ................................................... 22
Power Steering: System Pressure Test .................................................... 23
Power Steering: Bleeding the System ..................................................... 24
Power Steering: Pre-Loading the Steering Gear ...................................... 25
Power Steering: Special Tools ................................................................. 26
Suspension and Steering: Lab 1 ............................................................. 27
Engine Repair: Test Questions ................................................................ 28 SS-1
rev 02
5-4
M-Car:
Suspension
and Steering
Instructor Guide
rev 02
Suspension 5-5
M-Car:
Suspension
and Steering
Instructor Guide
Front Suspension
Application
Suspension type McPherson Strut type
Maximum length 475 ~ 481mm (18-19 in)

Shock
Absorber Minimum length 321 ~ 327mm (12.5-13 in)
Stroke 154mm (6 in)
Stabilizer bar outside diameter 24mm (0.9 in) SS-2
Coil spring height (No load) 374mm (14.7 in)
Grease type (Front wheel bearing and hub) M-8143 ANTIF BRG GREASE
Rear Suspension
Application
Suspension type Isolated trailing link
Maximum length 394.5 ± 3mm (15.5 ± .1in)

Shock
Minimum length 257.5 ± 3mm (10.1 ± .1in)
Absorber
Stroke 137mm (5.4 in)
Clearance 394.5 ± 3mm (15.5 ± .1in)

Rear wheel
bearing
No load 257.5 ± 3mm (10.1 ± .1in)
Coil spring height (No load) 291mm (11.5 in)
Grease type (Rear wheel bearing and hub) M-8143 ANTIF BRG GREASE
rev 02
5-6 Suspension: Front
M-Car:
Suspension
and Steering
Instructor Guide
SS-3
rev 02
Suspension: Front 5-7
M-Car:
Suspension
1. Strut Bar 19. Outer Bearing Oil Seal
and Steering
2. Front Suspension Strut 20. Rotor/Brake Disc
Assembly Instructor Guide
21. Wheel Hub
3. Strut Inner Support 22. Hub Bolt
4. Strut Mount Assembly 23. Hub Assembly
5. Strut Mount Seat 24. Drive Axle-to-Hub Caulking Nut
6. Strut Bearing Seat 25. Control Arm Ball Stud Bolt
7. Strut Bearing 26. Cotter Pin
8. Coil Spring Upper Seat 27. Castellated Nut
9. Coil Spring Seat 28. Washer
10. Bumper Stopper 29. Stabilizer Shaft Bushing
11. Coil Spring 30. Control Arm Dust Seal
12. Strut 31. Clip
13. Inner Bearing Oil Seal 32. Control Arm Bushing
14. Inner Hub Bearing 33. Control Arm Assembly
15. Steering Knuckle 34. Stabilizer Shaft
16. Dust Cover 35. Stabilizer Shaft Mount
17. Hub Bearing Spacer 36. Front Under Longitudinal Frame
18. Outer Hub Bearing
rev 02
5-8 Suspension: Front Toe Adjustment
M-Car:
Suspension
and Steering
Instructor Guide
1. Remove the clamps from both the rack and pinion boots.
2. Loosen the right and the left tie rod end lock nuts.
3. Turn the right and the left tie rod to align the toe. In this adjustment, the
right and left tie rods must be equal in length.
4. Tighten the tie rod end nut to 45Nm (33lb-ft)
5. Install RH and LH rack and pinion boot clamps
To adjust the front toe, turn both RH and LH tie rods in opposite directions
SS-4 equal amounts until proper toe is achieved. Ensure both tie rods are equal
length when finished.
rev 02
Suspension: Rear 5-9
M-Car:
Suspension
and Steering
Instructor Guide
1. Shock Absorber 9. Oil Seal

2. Bumper Stopper 10. Wheel Bearing Inner
3. Coil Spring Upper Seat 11. ABS Wheel Speed Ring SS-5
4. Coil Spring 12. Wheel Bearing Outer
5. Washer 13. Cotter Pin
6. Bushing 14. Castellated Nut
7. Lateral Rod 15. Spindle Cap
8. Rear Axle 16. Trailing Arm
rev 02
5-10 Suspension: Wheel Bearing Adjustment
M-Car:
Suspension
and Steering
Instructor Guide
Checking the Rear Wheel Bearing End Play

1. Release the parking brake
2. Raise the vehicle
3. Check the wheel bearing play by moving the top and bottom of the tire
in-and-out.
Rear wheel bearing play 0 mm (0 in)
4. If the bearing play is excessive, tighten the castellated nut.

5. If the bearing play is excessive after tightening, replace the wheel bearing.
SS-6
Rear Wheel Bearing Pre Load

1. Release the parking brake
2. Raise the vehicle and rotate the wheel
3. Remove the wheel
4. Check the torque when the hub moves by a spring scale.
0.137~ 0.422 Nm
Standard (No load)
(1-4 lb-in)
5. If the checked torque is not in specifications, tighten the castellated nut.
6. If the checked torque is not in specifications after tightening, replace the
wheel bearing.
rev 02
Suspension: Special Tools 5-11
M-Car:
Suspension
and Steering
DW 220-020A-01 DW 340-030 Instructor Guide

Differential Bearing Front Wheel Bearing
Puller Installer
DW 220-020A-04
KM 507-B
Differential Bearing
Ball Joint Remover
Plate Adapter
DW 340-010 009940-71430
Front Wheel Hub Front Spring
Remover Compressor
SS-7
DW 340-020
Front Wheel Beating
Race Installer
rev 02
5-12 Suspension: Special Tools
M-Car:
Suspension
and Steering
Instructor Guide
DW 340-010 DW 350-030
Front Wheel Hub Rear Wheel Bearing
Remover Installer
SS-8
rev 02
Suspension: Power Steering 5-13
M-Car:
Suspension
Application and Steering
Type Rack & Pinion Instructor Guide
With Air bag 380 mm (15 in)

Diameter
Steering wheel Without Air bag 370 mm (14.5 in)
Free play (Engine stop) 0 ± 20 mm ( 0 ± 0.79 in)
Overall gear Manual steering 21.1 : 1

ratio
Power steering 15.7 : 1
Lubricant DEXRON-II, III

Power steering
Capacity 1.0 liter (34 oz)
pump
Type Vane
Inside 39.5° ± 2°
144, 155 Tire
Steering wheel Outside 33.5° ± 2°
angle
Inside 34.9° ± 2°
175 Tire
Outside 30.5° ± 2°
Rack POLYUREAS
Grease
SYNTHETICS OILS & LI
Ball Joint
SOAPS
rev 02
5-14 Power Steering
M-Car:
Suspension
and Steering
Power Steering System
The power steering system is equipped with a hydraulic booster that reduces
Instructor Guide the force required to operate the steering wheel.
The power steering system consists of the following three major parts;
1. Pump: Generates hydraulic pressure.
2. Control valve: Switches the fluid direction to the power cylinder
depending on the rotational direction of the steering wheel.
3. Power cylinder: Moves the piston in the cylinder right or left with hydraulic
force, and thereby assists the steering wheel operation.
Operation
When the steering wheel is turned, hydraulic pressure from the pump is
shifted by the control valve and drawn into the power cylinder piston.
Hydraulic pressure pushes the piston to the right or left depending on
steering wheel rotation, assisting the steering wheel so that it can be
operated easily.
SS-9 Reservoir
Cooler
Pump
Control Valve
Power Cylinder
rev 02
Power Steering: Pump 5-15
M-Car:
Suspension
Reservoir Side Generally, there are two types of
and Steering
pumps used for the power steering
Chamber A system. Instructor Guide
Gear Type Pump

As the gears turn, fluid in the chamber
(A) enters the tooth groove of each gear
and flows along the inner circumference
of the pump to the chamber (B)
As the two gears engage in the chamber
(B), fluid in the tooth grooves is emptied
into the control valve.
Chamber B
Control Valve Side

Rotational direction of gear
Flow of fluit
Vane-Type Pump
Cam Ring The vane-type pump consists of an oval
cam ring, rotor and vanes. The vanes SS-10
rotate on the inner circumference of the
Vane cam ring, pushed by the centrifugal
force of the rotor.
Fluid is discharged to the control valve
as the rotor turns and the volume of
Rotor each vane chamber decreases.
This intake/ discharge operation is
performed at the top and bottom
Vane sections of the drawing. Each vane
Chamber chamber performs two intake/discharge
operations for every rotation of the rotor.
Rotational direction of gear

Flow of fluit
rev 02
5-16 Power Steering: Control Valve Unit
M-Car:
Suspension
The control valve unit consists of the two sections:
and Steering
Instructor Guide When the steering wheel is turned, a torsion bar twists depending on the
reaction force of the road surface. This, in turn, produces the gap between
the input shaft and valve. The fluid passage diameter changes depending on
this gap and controls the flow volume.
The input shaft and pinion shaft are engaged by the loose splines preventing
the torsion bar from twisting more than the set angle.
Difference in Angle
Convex on Valve
Concave
in Valve
Input Shaft
Torsion Bar
Input Shaft
Valve
SS-11
To Right Power
Cylinder
From From Pump
Pump
To Left Power
To Cylinder
Reservoir
Pinion Shaft To Reservoir
rev 02
Power Steering: Control Valve Operation 5-17
M-Car:
Suspension
When the Steering Wheel and Steering
is Not Operated Reservoir
When the steering wheel is not operated, Pump Instructor Guide
the input shaft is in the neutral position and
fluid from the pump returns to the reservoir Input
Torsion Shaft Valve
through the rotary valve. Bar
Rotary
Valve
Power Cylinder
(Neutral)
SS-12
When the Steering Wheel

is Operated Pump Reservoir
When the steering wheel is turned

Input
counterclockwise, the input shaft also turns Torsion Shaft
counter clockwise, opening the passage on Bar Valve
the power cylinder side.
Fluid flows through the rotary valve to the
power cylinder chamber (A). Fluid in
chamber (B) is discharged by the piston and
returns to the reservoir. Chamber
B
Likewise, when the steering wheel is turned Chamber
clockwise, the input shaft also turns A
clockwise, opening the valve passage on the Power Cylinder
(When Operation)
power cylinder chamber’s (B) side.
Rotation Direction
This operation is possible because of the Flow of Fluid (intake)
three segments on the circumference of the Flow of Fluid (Return)
input shaft and valve which are
interconnected with the fluid passages.
rev 02
5-18 Power Steering: Pressure Switch
M-Car:
Suspension
and Steering Fenix Electronic Control
5MR Module (ECM)
Instructor Guide
Power Steering
Oil Pressure
Switch
Sirius Electronic Control

D3 Module (ECM)
Power Steering
Oil Pressure
SS-13 Switch
rev 02
Power Steering: Steering Column 5-19
M-Car:
Suspension
and Steering
Instructor Guide
SS-14
1. Horn Cover (Airbag Module) 14. Bolt

2. Steering Wheel Nut 15. Support Bolt
3. Locking Plate 16. Steering Column Housing
4. Steering Wheel 17. Steering Column Jacket
5. Steering Column Upper Cover 18. Ignition Switch Retaining Screw
6. Steering Column Lower Cover 19. Ignition Switch
7. Turn Signal Switch 20. Steering Lock Housing
8. Windshield Wiper Switch Assembly
9. Steering Column Assembly 21. Steering Column Shaft
10. Retaining Ring 22. Pinch Bolt
11. Washer 23. Intermediate Shaft
12. Spring 24. Steering Column Upper Nut
13. Switch Housing 25. Steering Column Lower Nut
rev 02
5-20 Power Steering: Gear Parts
M-Car:
Suspension
and Steering
Instructor Guide
SS-15
1. Rack and Pinion Assembly 9. Lock Nut

2. Tie Rod Boot 10. Tie Rod End
3. Tie Rod Boot 11. Castellated Nut
4. Tie Rod 12. Cotter Pin
5. Mounting Flange 13. Packing
6. Mounting Flange 14. Pinion Shaft with Bearing
7. Cover 15. Bearing
rev 02 8. Packing 16. Rack Gear
Power Steering: Rack 5-21
M-Car:
Suspension
and Steering
Instructor Guide
SS-16
1. Power Steering Oil Reservoir 10. Clip

2. Power Steering Oil Reservoir Cap 11. Supply Line Hose
3. Power Steering Oil Reservoir 12. Power Steering Pump Assembly
Shield 13. Power Steering Pump
4. Return Line 14. Front Bracket
5. Clamp 15. Power Steering Pump Pulley
6. O-Ring 16. Rear Bracket
7. Gear Pressure Pipe 17. Main Bracket (A/C & P/S)
8. Pump Pressure Pipe 18. Power Steering Pump Bracket
9. Power Steering Gear (Non A/C)
rev 02
5-22 Power Steering: Straight Ahead Check
M-Car:
Suspension
and Steering Outside Angle Inside Angle
Instructor Guide Front
After all necessary operations on the steering gear are completed, check the
exact straight-ahead position of the steering as follows.
With the vehicle on the floor, place the steering wheel in the straight-ahead
position. Mark the centerline of both tires on the floor. Turn the steering
wheel all the way to the right and mark the new centerline of both tires on the
floor.
Application Tire Specified value

SS-17 145.155 37.5 ~ 41.5
o
Inside angle
o
175 32.9 ~ 36.9
o
145.155 31.5 ~ 35.5
Outside angle
o
175 28.5 ~ 32.5
rev 02
Power Steering: System Pressure Test 5-23
M-Car:
Suspension
and Steering
Instructor Guide
Check the fluid pressure as follows to determine whether the trouble is in the
pump or the gear unit
1. Check the power steering fluid level and the pump drive belt tension.
2. Disconnect the high pressure line at the pump. Use a small container to
catch any fluid
3. Connect the hose of the pressure gauge kit (DW310-030A) to the power
steering pressure hose from the power steering pump
4. Place the gear selector lever in NEUTRAL. Set the parking brake.
5. Open the gauge valve fully
6. Start the engine and let it idle
SS-18
7. Turn the steering wheel from lock-to lock several times to warm the fluid
to normal operating temperature.
*If the valve is fully closed for more than 10 seconds the power steering pump
could be damaged.
8. Close the gauge-valve fully, and read the pressure.
Pump Relief Valve
5,197.7- 5,688.1 kPa (754-825 psi)
Pressure
9. Immediately open the gauge-valve fully and read pressure
Pump Pressure Pre-Load 294.1- 490.3 kPa (43-71 psi)
10. If the pressure is not within the specified limits, replace the power
steering pump. If within limits the problem is not in the pump.
rev 02
5-24 Power Steering: Bleeding the System
M-Car:
Suspension
If the power steering hydraulic system has been serviced, an accurate
and Steering
fluid level reading cannot be obtained until the air is bled from the
Instructor Guide system
1. Turn the wheels all the way to the left and add the power steering fluid*
to the MIN mark on the fluid level indicator.
* When adding fluid or making a complete fluid change, always use
DEXRON-II or III power steering fluid. Failure to use the proper fluid will
cause hose and seal damage and fluid leaks.
2. Start the engine. Check the fluid level with the engine running at fast idle.
If necessary, add fluid to bring the level up to the MIN mark.
3. Bleed the system by turning the wheels from side to side without
reaching the stop at either end. Keep the fluid level at the MIN mark. The
air must be eliminated from the fluid before normal steering action can be
obtained.
4. Return the wheels to the center position. Continue running the engine
for 2 to 3 Minutes.
5. Road test the car to be sure the steering functions normally and is free
from noise.
5. Recheck the fluid level as described in steps 1and 2. Make sure the fluid
level is at the MAX mark after the system has stabilized at its normal
operating temperature. Add fluid as needed
rev 02
Power Steering: Pre-Loading the Steering Gear 5-25
M-Car:
Suspension
and Steering
Instructor Guide
Adjustment Procedure
1. Place the steering wheel in the straight- ahead position.
2. Raise and suitably support the vehicle
3. Check the torque of the adjustment plug
4. Adjust the tightening torque if the measured torque is above or below the
specified value.
• Place the rack gear in the straight -ahead position
• Tighten the adjust plug to 10Nm (7 lb/ft)
• Turn the steering wheel all the way to the right and the left about 5
times repeatedly.
SS-19
• Place the rack gear in the straight- ahead position
• Loosen the adjust plug
• Tighten the adjust plug to 4.5 - 5.5 Nm (3.4 lb/ft)
• Loosen the adjust plug to 67.5o
6. Tighten the adjust plug locknut.
rev 02
5-26 Power Steering: Special Tools
M-Car:
Suspension
and Steering
Instructor Guide
DW310-030A
Pressure Test Gauge
DW310-020
Power Steering Pulley
Steering Holder
SS-20
KM-507-B
Ball Joint Remover
DW310-010
Steering Wheel Puller
rev 02
M-Car
Brakes
Instructor Guide
M-Car:
Brakes
Brakes: Brake System ............................................................................... 4
Instructor Guide
Brakes: Front Brakes................................................................................. 5
Brakes: Rear Brakes (Drum) ..................................................................... 6
Brakes: Parking Brake .............................................................................. 7
Brakes: Master Cylinder ............................................................................ 8
Brakes: Fluid Lines (ABS) ......................................................................... 9
Brakes: Lining Inspection ........................................................................ 10
Brakes: Rotor Inspection ......................................................................... 11
Brakes: Specifications ............................................................................. 12
Brakes: Need for ABS ............................................................................. 13
Brakes: ABS Stop ................................................................................... 14
Brakes: Electronic Brake Distribution ...................................................... 15
Brakes: Introduction of the EBC 430 ....................................................... 16
Brakes: ABS System Block Diagram....................................................... 17
Brakes: Wheel Speed Sensor ................................................................. 18
ABS System Components ....................................................................... 20
Brakes: Hydraulic Control Unit ................................................................ 21
ECBM ...................................................................................................... 22
Brakes: Isolation Valve / Dump Valve ..................................................... 23
Brakes: LPA / HPA .................................................................................. 25
Brakes: Return Pump Motor / Return Pump ............................................ 26
Brakes: ABS Warning Light ..................................................................... 27
Brakes: Normal Brake Mode ................................................................... 28 BR-1
Brakes: Isolation Mode (Pressure Maintain) ........................................... 29
Brakes: Dump Mode (Pressure Decrease) ............................................. 30
Brakes: Reapply Mode (Pressure Increase) ........................................... 31
Brakes: Proportioning Function ............................................................... 32
DTC ......................................................................................................... 33
Brakes: Diagnostic Trouble Codes (DTC) ............................................... 34
Brakes: ABS (Sirius D3) .......................................................................... 35
Brakes: ABS (FENIX 5MR) ..................................................................... 36
Brakes: Lab 1 .......................................................................................... 37
Brakes: Test Questions ........................................................................... 38
rev 02
6-4
M-Car:
Brakes
Instructor Guide
rev 02
Brakes: Brake System 6-5
M-Car:
Brakes
Instructor Guide
Size 177.8 mm
Booster
Ratio 3.7 : 1
Type Tandem
Master
cylinder 20.64 mm
Bore Diameter
(.812 in)
2,451.6 kPa
Cut-In pressure
Proportioning (356 psi)
valve
Pressure ratio 0.25 : 1
Disc type Solid Rotor

Front brake
236 mm
Rotor diameter
(9.3 in)
Inside 180 mm
diameter (7.1 in)
Rear Drum
brake type Wheel cylinder 17.46 mm
diameter (0.687 in)
Specification DOT-3 or DOT-4

Fluid
0.45L
Capacity
(15 oz)
rev 02
6-6 Brakes: Front Brakes
M-Car:
Brakes
Instructor Guide
1. Front Brake Caliper Assembly

2. Front Brake Cylinder Assembly
3. Pins
4. Pin Boots
5. Front Brake Pads
6. Carrier
7. Pad Spring
8. Piston Boot
9. Piston
10. Piston Seal
11. Cylinder
12. Bleeder Screw Cover
rev 02
13. Bleeder Screw
Brakes: Rear Brakes (Drum) 6-7
M-Car:
Brakes
Instructor Guide
1. Bleeder Screw 9. Upper Return Spring

2. Bleeder Screw Cover 10. Brake Shoe Retain Spring Pin
3. Rear Brake Shoes 11. Trailing Shoe
4. Rear Brake Plate 12. Brake Shoe Retain Spring
5. Wheel Cylinder 13. Brake Shoe Retain Spring Cap
6. Adjuster Assembly 14. Lower Return Spring
7. Brake Leading Shoe 15. Hub Bolt
8. Middle Return Spring 16. Rear Brake Drum
rev 02
6-8 Brakes: Parking Brake
M-Car:
Brakes
Instructor Guide
1. Parking Brake Lever Assembly

2. Parking Brake Cable
3. Strengthener
4. Locking Clip
5. Anchor Bolt
6. Pin
7. Cable Pully
8. Cotter Pin
9. Cable Lock
rev 02
Brakes: Master Cylinder 6-9
M-Car:
Brakes
Instructor Guide
1. Power Booster (Servo) 8. Master Cylinder Assembly

2. Power Booster Servo Boot 9. Fluid Reservoir Assembly
3. Cotter Pin 10. Reservoir Cap
4. Clevis 11. Reservoir
5. Clevis Pin 12. Grommet Seal
6. Packing 13. Master Cylinder
7. Spacer 14. Proportioning Valve
15. junction Block
rev 02
6-10 Brakes: Fluid Lines (ABS)
M-Car:
Brakes
Instructor Guide
1. ABS Control Unit

2. Brake Booster
3. Rear Drum Brake Assembly
4. Front Disc Brake Assembly
rev 02
Brakes: Lining Inspection 6-11
M-Car:
Brakes
LINING INSPECTION
1. Raise and suitably support the vehicle. Instructor Guide
2. Remove the front wheels.
3. Visually check the linings for minimum thickness and wear.
4. Measure the thickness.
Important: The minimum thickness of the shoe and lining together is 8
mm (0.31 in.)
5. Install the shoe and linings in axle sets only.
6. Install the front wheels.
7. Lower the vehicle.
ROTOR INSPECTION
Thickness variation can be checked by measuring the thickness of the rotor
at four or more points around the outer braking surface of the rotor. All
measurements must be made at the same distance in from the edge of the
rotor.
If the thickness of the rotor is below 10 mm (0.40 in.), replace the brake rotor.
During manufacturing, the brake rotor and the tolerances of the braking
surface regarding flatness and lateral runout are held very close. The
maintenance of close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
In addition to these tolerances, the surface finish must be held to a specified
range. The control of the braking surface finish is necessary to avoid pulls
and erratic performance and to extend lining life.
Using a commercially-available dial indicator, check lateral runout as follows:
Notice: Permissible lateral runout is a maximum 0.05 mm (0.002 in.). If lateral
runout exceeds the specification, ensure there is no dirt between the rotor
and the hub and that contact surfaces are smooth and free from burrs.
rev 02
6-12 Brakes: Rotor Inspection
M-Car:
Brakes
1. Position the transaxle in NEUTRAL.
Instructor Guide 2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten a dial indicator to the strut.
4. Set the gauge probe tip to approximately 10 mm (0.4 in.) from the outer
edge of the brake rotor, perpendicular to the disc and under slight
preload.
5. Rotate the rotor to measure Lateral Run-out.
6. Remove the dial indicator.
Important: Since accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes, refinishing of the rotor should be
done only with precision equipment.
7. Refinish the rotor, if required, with precision equipment. Discard the rotor
if it fails to meet the above specifications after refinishing.
8. Install the rotor.
rev 02
Brakes: Specifications 6-13
M-Car:
Brakes
Specifications
Instructor Guide
Application Specification Remarks
Model EBC 430 Lucas Varity
4 sensor 4
Sensor/Channel
channel
Number of Speed ring teeth 40
ABS relay operation voltage 9.5 - 16 V
Air gap 0.4 - 1.0 mm
Resistance 1,000 - 1,500 20°C (68°F)
Insulation
Front wheel speed
resistance
sensor
Spinning the
A/C voltage Above 0.1 V
wheel by hand
0.4 - 1.0 mm
Air gap
(.002-.039 in)
Rear wheel speed Resistance 1,000 - 1,500 20°C (68°F)
sensor Insulation
resistance
Spinning the
A/C voltage Above 0.1 V
wheel by hand
Grade DOT 3
Capacity (L) 0.45 L (15 oz)
Brake fluid Every 20,000km
Maintenance
(12,500 mi) or 2
interval
years
rev 02
6-14 Brakes: Need for ABS
M-Car:
Brakes
Instructor Guide Stable Unstable Area
Area
Longitudinal Brake
Friction Coefficient Force Coefficient
Mb
Wheels Go to Lock
Lateral Brake
Force Coefficient
Ms
Wheel Slip Percentage

The force applied to the driving surface by a vehicle wheel following the
driver's command for acceleration, steering and deceleration has two
components:
1. Lateral force.
2. Brake (longitudinal) force.
These forces depend on two friction coefficients:
1. Lateral force coefficient: ms
2. Braking force coefficient: mb
These coefficients vary with the slippage between wheel and driving surface
as shown above. The curve values and shape differ greatly as a function of
surface and tire condition.
The purpose of an ABS system is to keep the wheel slip in the range of that
curve optimizing vehicle braking while retaining steerability and stability. This
is accomplished by limiting the braking force commanded by the driver when
it would cause excessive slip.
rev 02
Brakes: ABS Stop 6-15
M-Car:
Brakes
Instructor Guide
Vehicle Speed
Speed in km/h
Wheel Speed
Master Cylinder Pressure
Wheel Pressure
Time in ms
1. When the driver depresses the brake pedal, the pressure in each of the
individual brakes increases with the master cylinder pressure, the vehicle
and wheel speeds decrease. When the decrease in vehicle speed is
slower than the decrease in wheel speed, wheel skid can result.
2. When the system senses the difference between car and wheel speed
becoming excessive, it energizes the isolation valve and prevents brake
pressure from increasing further, regardless of master cylinder pressure.
This process reduces the chance of skid.
3. If the EBCM detects that the wheel speed continues to depart
significantly from the true vehicle speed the dump valve is energized and
pressure in the brake is relaxed by the evacuation of fluid. This allows the
wheel speed to increase preventing wheel skid. The dump valve closes
and the isolation valve remains closed keeping the wheel pressure
constant.
4. When the wheel speed increases and gets closer to car speed the ABS
system starts a "pulsing" sequence to force the wheel pressure to
increase in steps by intermittent opening of the isolation valve.
5. This cycle: steps 1-3 repeat until the brake pedal is released or a low
enough speed is reached that the ABS function is deactivated.
rev 02
6-16 Brakes: Electronic Brake Distribution
M-Car:
Brakes
Ideal distribution
Instructor Guide Critical break points fully loaden vehicle
Relative rear brake force
Ideal distribution
lightly loaden vehicle
Advanced distribution
with Lucas Varity ABS
Regular distribution
without DRP
Relative front brake force

EBC 430 features an enhanced algorithm that includes control of the brake
force distribution between the front and rear axles. This is called Electronic
Brakes Distribution or Dynamic Rear Proportioning and replaces the
conventional proportioning valve. Brake efficiency is comparable to a
conventional system for an empty vehicle. The efficiency of the DRP system is
higher for a fully loaded vehicle due to the better use of rear axle braking
capability.
No indication is given to the driver when DRP is activated
Also, DRP remains active even when the anti-lock function of the ABS is
disabled.
NOTE: There is a risk of rear over braking if full brake pressure is applied and
the ABS controller or its power supply circuit is disconnected from the vehicle
harness. In this case the vehicle might become unstable under some
circumstances. Consequently, contacting an authorized dealer is
recommended when the ABS warning light comes on.
rev 02
Brakes: Introduction of the EBC 430 6-17
M-Car:
Brakes
EBC 430 is the Lucas Varity's four-wheel, four-channel ABS system for
diagonal as well as front & rear split brakes in passenger car applications. It Instructor Guide
features active circuits for both front and rear axles and integrated, yet
separately serviceable electronics. It also has an Electro Hydraulic Control
Unit comprising the Electronic Brake Control Module (EBCM) and a Hydraulic
Control unit (HCU)
Master cylinder RR Wheel speed sensor
Hydraulic control unit
RL Wheel Speed sensor

FR Brake caliper
FL Wheel speed sensor
rev 02
6-18 Brakes: ABS System Block Diagram
M-Car:
Brakes
Battery ABS warning lamp
Instructor Guide
Ignition EBD warning lamp

(Parking brake lamp)
Ground Valve
Valverelay
relay
Electrinic
Wheel speed Brake Control Motor relay
sensor (4) Module
Brake switch Inlet valve (4)
Motor monitoring Outlet valve (4)
Ground monitoring DLC
rev 02
Brakes: Wheel Speed Sensor 6-19
M-Car:
Brakes
Instructor Guide
Front Wheel
Speed Sensor
Rear Wheel
Speed Sensor
Specifications of the Wheel Speed Sensor
Appication Specification Remarks
0.5~1.2 mm
Air gap
(.020-.047 in)
Resistance 1.6§Ú ¡ ¾32Ω at 20ºC (68ºF)
Insulation Resistance ∞Ω
Turn wheel slowly

AC voltage by hand (2.78
120 mV
km/h)(1.73 mph)
rev 02
6-20 Brakes: Wheel Speed Sensor
M-Car:
Brakes
Wheel Speed Sensor
Instructor Guide Each wheel has a toothed ring that rotates past a magnetic wheel speed
sensor.
• As the toothed ring rotates, the wheel speed sensor generates an AC
voltage signal whose frequency is proportional to the wheel speed. The
faster the wheel goes, the higher the frequency.
• The EBCM uses wheel speed sensor signals to determine whether one
or more of the wheels are decelerating too rapidly, indication that wheel
lockup is about to occur.
Speed Sensor
Air Gap
Speed Sensor Signal and EBCM
rev 02
ABS System Components 6-21
M-Car:
Brakes
Instructor Guide
1. ABS Hydraulic Control unit 6. Lower Mount Bracket

2. Electronic Brake Control Module 7. Bracket Grommet
3. Bolt 8. Rear Wheel Speed Sensor
4. Upper Mount Bracket 9. Front Wheel Speed Sensor
5. Grommet
rev 02
6-22 Brakes: Hydraulic Control Unit
M-Car:
Brakes
The HCU body is a single casting which contains all isolation and dump
Instructor Guide valves, high pressure attenuators (HPA), low pressure accumulators (LPA),
pump elements, and the pump motor. The HCU body is the holding element
for the complete unit and is attached to the car body by a bracket.
HCU: Hydraulic Control Unit
HPA: High Pressure Attenuator
LPA: Low Pressure Accumulator
EBCM
Dump Valve
Isolation Valve Return Pump

Motor
Return Pump
HPA
Return Pump
LPA
HPA
rev 02
ECBM 6-23
M-Car:
Brakes
Electronic Brake Control Module
A connector drawing shows figure. It has 31 pins. For removal and Instructor Guide
installation it is necessary to latch / unlatch the locking lever. One particular
feature is that includes a warning switch which grounds and lights the ABS
warning lamp if there is NO ABS unit plugged in, so that an indication is given
that ABS is not available.
Mechanical Pin Mechanical

Switch
Pin Signal Name Color Circuit

ROUGH Buffered wheel speed sensor : to ECM-55
2 GrY
ROAD (Sirius D3)
9 RRWSHI Br Right rear wheel speed high
10 RRWSLO W Righr rear wheel speed low
11 SDLUART BrG Serial data link
12 RFWSHI GB Right front wheel speed high
13 RFWSLO BrG Right front wheel speed low
14 LFWSHI L Left front wheel speed high
15 IGN RY Switched ignition
16 GND B Negative battery terminal
17 BATT R Battery
18 BATT R Battery
19 GND B Negative battery terminal
20 ABSWARN GGr ABS warning indicator
22 LRWSHI B Left rear wheel speed high
23 LRWSLO R Left rear wheel speed low
24 BRAKESW Y Brake switch
25 LFWSLO Y Left front wheel speed low
rev 02
6-24 Brakes: Isolation Valve / Dump Valve
M-Car:
Brakes
Isolation Valve
Instructor Guide The isolation valve is placed in the brake fluid path from the master cylinder to
the relevant brake caliper and allows free flow as commanded by the driver
during normal braking and reapply phases.
Each wheel has a toothed ring that rotates past a magnetic wheel speed
sensor.
In the isolation phase a coil moves the armature down and closes the
normally open isolation orifice and prevents any further increase of pressure
on the brakes.
The valve also remains closed during the dump phase. The lip seal provides a
one way return path for brake fluid to flow through in:
1. The foot off pedal isolation
2. The residual Low Pressure Accumulator (LPA) fluid.
Piston
Ball
Spring
Seal
To Caliper
To Dump Valve
Wheel Cylinder
Ring Channel
Lip Seal
From Master
Cylinder
rev 02
Brakes: Isolation Valve / Dump Valve 6-25
M-Car:
Brakes
Dump Valve
The dump valve creates a flow path from the isolation valve (brake side) to the Instructor Guide
low pressure accumulator (LPA). The valve keeps this path permanently
closed except during the pump phase of the ABS mode.
On activation (dump phase), the coil moves up the armature which opens the
normally closed dump orifice and allows the pressure in the brake line to
drain as brake fluid flows into the LPA.
The lip seal provides a return path for residual brake fluid in the LPA.
LPA: Low Pressure Accumulator
Spring
Piston
Ball Seat
Seat
To Caliper
Isolation Valve Filter
Lip Seal
To LPA/
Return Pump
rev 02
6-26 Brakes: LPA / HPA
M-Car:
Brakes
Low Pressure Accumulator (LPA)
Instructor Guide LPA provides a variable chamber for brake fluid
to be quickly pushed in through the dump valve
at the beginning of a cycle. This chamber then
acts as a reservoir which buffers the pump.
To Master
Cylinder
From Cump
Valve
High Pressure Attenuator (HPA)

The HPA is between the pump and the Isolation Valve (ISO) (master cylinder
side). It uses the bulk mode of the built-in plastic damper and the orifice size
to dampen the pressure oscillations from the pump. This reduces feed back
to the master cylinder and brake pedal.
To Isolation
Valve
To Master
Cylinder
rev 02
Brakes: Return Pump Motor / Return Pump 6-27
M-Car:
Function: Brakes
The motor drives the two pump
Instructor Guide
elements through the eccentric wheel on
its shaft.
Description: Each pump element
consists of a fixed displacement piston
driven by an eccentric on the end of the
electric motor, and is fed with fluid by the
low pressure accumulator.
Operation:
Compression Stroke:
The pump is filled via the inlet ball seat,

then the motor eccentric rotates moving
the piston to displace the fluid. After the
pressure build- up closes the inlet valve
the piston displacement increases the
pressure until the outlet ball opens. The
outlet pressure will continue to increase
for the rest of the piston stroke.
1. Spring 7. Sleeve
2. O-Ring 8. Seal
Return Stroke:
3. HPA 9. Ball Outlet
The piston retracts, forced by its spring,
4. LPA 10. Spring
as the motor eccentric returns to its low
5. Filter 11. Plug-Pump Sleeve
end position. The pressure at the inlet 6. Piston
side of the outlet ball then decreases
due to the displaced volume and the
pressure difference across this ball holds
it closed.
The pressure at the outlet side of the
inlet ball seat, which is set to open at a
certain pressure level also decreases
until this valve opens . With the outlet
ball closed, the pump is filled with
additional fluid from the low pressure
1. HPA
accumulator.
2. LPA
The process will continue until a stall 3. 3-4 mm
point is reached and compression of the 4. Return Pump
piston cannot anymore to open the 5. Return Pump Motor
outlet ball seat.

HPA : High Pressure Attenuator
LPA : Low Pressure Accumulator
rev 02
6-28 Brakes: ABS Warning Light
M-Car:
Brakes
The ABS warning lamp in the IP has two functions:
Instructor Guide 1. It illuminates for four (4) seconds immediately after the ignition key has
been turned on to show that the anti-lock system self test is being
performed. If the lamp does not go off after this time it means that there
may be a problem and ABS operation is not available.
2. If any malfunction or error, including an unplugged EBCM connector, is
detected during vehicle operation, the lamp will come on, warning the
driver that the ABS is not operative and brake operation is in
conventional, non- ABS mode.
rev 02
Brakes: Normal Brake Mode 6-29
M-Car:
Brakes
During non-antilock braking, pressure is applied through the brake pedal and
fluid comes from the master cylinder into the hydraulic unit. The normally Instructor Guide
open isolation cartridge and normally closed dump cartridge will remain in
these positions to allow fluid pressure to the calipers and the wheel cylinders
until each wheel begins locking
Master
Cylinder
HPA Return HPA

Pump Motor
Return
Pump
FL Isola- RR Isolation
tion Valve Valve
LPA LPA
RR Isolation RL
Valve Isolation
RR Dump FR Dump Valve
Valve Valve
FL Dump Valve RL Dump Valve
rev 02
6-30 Brakes: Isolation Mode (Pressure Maintain)
M-Car:
Brakes
If the information from the wheel speed sensors indicates excessive wheel
Instructor Guide deceleration (imminent lock up), the first step in the antilock sequence is to
isolate the brake pressure being applied by the driver. The EBCM sends a
signal (voltage) to the coil to energize and close the isolation valves by pulling
down on the armature. This prevents any additional fluid pressure applied by
the driver from reaching the wheel. Though each channel of the 4 channel
system can operate independently, once any front channel (brake) sees
excessive deceleration, both front isolation valves energize and close. The
closing of the isolation valves prohibits further increases in the brake
pressure.
Master
Cylinder
HPA Return HPA

Pump Motor
Return Return
Pump Pump
tion Valve Valve
LPA LPA
RR Isolation RL
Valve Isolation
Valve Valve
rev 02
Brakes: Dump Mode (Pressure Decrease) 6-31
M-Car:
Brakes
Once the pressure is isolated, it must be reduced to get the wheels rolling
again. This is accomplished by dumping a portion of the brake fluid pressure Instructor Guide
into a low-pressure accumulator (LPA). The EBCM energizes the dump valve
coil(s) to open the dump valve and allow fluid from the wheels to be dumped
into the LPA. This is done with very short activation pulses opening and
closing the dump valve passageway. Brake pressure is lowered at the wheel
and allows the wheel to begin turning again. The fluid taken from the wheels
forces the spring back in the LPA and also primes the pump. The dump
valves are operated independently to control the deceleration of the wheels.
Master
Cylinder
HPA Return HPA

Pump Motor
Return Return
Pump Pump
tion Valve Valve
LPA LPA
RR Isolation RL
Valve Isolation
Valve Valve
rev 02
6-32 Brakes: Reapply Mode (Pressure Increase)
M-Car:
Brakes
The reapply sequence is initiated to obtain optimum braking. The isolation
Instructor Guide valve is momentarily pumped open to allow master cylinder and pump
pressure to reach the brakes. The controlled pressure rise continues until the
wheel is at optimum brake output or until the brake pressure is brought up to
the master cylinder output pressure. If more pressure is required, more fluid is
drawn from the master cylinder and applied to the brakes. It is normal for the
driver to feel slight pedal pulsation, or pedal drop. As fluid pressure is
reapplied to the wheel, they begin to slow down. If they approach imminent
lockup again, the EBCM will isolate, dump and reapply again. The control
cycle (isolation, dump, reapply) occurs in milli-second intervals, allowing
several cycles to occur each second. It is a much faster and more controlled
way of "Pumping the pedal".
Master
Cylinder
HPA Return HPA

Pump Motor
Return Return
Pump Pump
tion Valve Valve
LPA LPA
RR Isolation RL
Valve Isolation
Valve Valve
rev 02
Brakes: Proportioning Function 6-33
M-Car:
Brakes
If the rear wheels lock during braking, the vehicle may lose stability. The
ECM processes the speed sensor and brake signals to determine when Instructor Guide
the rear wheels are tending to lock up in order to prevent this. The EBCM
then actuates the rear wheel isolation valves to reduce the rear brake
pressure and keep the wheels rolling.
Master
Cylinder
HPA Return HPA

Pump Motor
Return Return
Pump Pump
tion Valve Valve
LPA LPA
RR Isolation RL
Valve Isolation
Valve Valve
rev 02
6-34 Brakes: Diagnostic Trouble Codes (DTC)
M-Car:
Brakes
DTC DESCRIPTION
Instructor Guide 0354 LF open or shorted sensor
0355 LF missing sensor or tone ring
0356 LF sensor drop-out
0404 RF open or shorted sensor
0405 RF missing sensor or tone ring
0406 RF sensor drop-out
0454 LR open or shorted sensor
0455 LR missing sensor or tone ring
0456 LR sensor drop-out
0504 RR open or shorted sensor
0505 RR missing sensor or tone ring
0506 RR sensor drop-out
0601 LF shorted DMP or open driver
0602 LF open DMP or shorted driver
0651 LF shorted ISO or open driver
0652 LF open ISO or shorted driver
0701 RF shorted DMP or open driver
0702 RF open DMP or shorted driver
0751 RF shorted ISO or open driver
0752 RF open ISO or shorted driver
0801 LR shorted DMP or open driver
0802 LR open DMP or shorted driver
0851 LR shorted ISO or open driver
0852 LR open ISO or shorted driver
0901 RR shorted DMP or open driver
0902 RR open DMP or shorted driver
0951 RR shorted ISO or open driver
0952 RR open ISO or shorted driver
1102 Open pump motor
1103 Bad motor driver
1104 Shorted pump motor
rev 02
Brakes: Diagnostic Trouble Codes (DTC) 6-35
M-Car:
DTC DESCRIPTION Brakes
1211 Shorted relay Instructor Guide

1212 Open relay
1213 Bad relay driver
1610 Stuck or inoperative brake switch
2321 Yellow warning lamp shorted to battery
2322 Yellow warning lamp shorted to ground
2458 Wheel speed error
2459 Mismatched wheel speeds
2520 Wheel speed difference 8/16 bit CPU
5501 Vehicle inhibit code
5502 ISO time-out
5503 CPU loop time error
5504 Excessive DMP time
5560 Inoperative external watch dog
5610 RAM/ROM error 8 bit
5630 ROM error 16 bit
5640 RAM error 16 bit
8001 Valve coil circuit - battery voltage > 16.0V
8002 Valve coil circuit - battery voltage < 9.0V
8003 Valve coil circuit - battery voltage < 9.5V
CPU: Central Processing Unit

DMP: Dump Valve
DTC: Diagnostic Trouble Code
ISO: Isolation Valve
RAM: Random Access Memory
ROM: Read Only Memory
rev 02
6-36 Brakes: ABS (Sirius D3)
M-Car:
Brakes
Instructor Guide
Wheel Speed
Cluster Sensor Front
ABS
Warning
Lamp
Stop
Lamp
Switch
Stop
SIG Ground
Stop Oil Feeding

lamp Connector
(Assembly
Line Only)
Wheel Speed
Sensor Rear
rev 02
Brakes: ABS (FENIX 5MR) 6-37
M-Car:
Brakes
Instructor Guide
Wheel Speed
Cluster Sensor Front
ABS
Warning
Lamp
Stop
Lamp
Switch
Stop
SIG Ground
Stop Oil Feeding

lamp Connector
(Assembly
Line Only)
Wheel Speed
Sensor Rear
rev 02
M-Car
Electrical
Instructor Guide
M-Car:
Electrical
Supplemental Restraints System (SRS).................................................... 5
SRS System: Airbag Deployment Condition ............................................. 6 Instructor Guide
SRS System: Deployment Time Table ....................................................... 7
SRS System: Electronic Sensing .............................................................. 8
SRS System: General Precautions ............................................................ 9
SRS System: Components ...................................................................... 10
SRS System: Steering Wheel Coil Module .............................................. 14
SRS System: Sensing and Diagnostic Module ....................................... 15
SRS System: Wiring Harness .................................................................. 17
SRS System: Air Bag Warning Lamp ....................................................... 18
SRS System: Diagnostic Fault Codes (DTC) .......................................... 19
SRS System: Diagnosis .......................................................................... 20
SRS System: Circuit Diagram ................................................................. 27
Keyless Entry: Introduction ...................................................................... 28
Keyless Entry: System Diagram .............................................................. 29
Keyless Entry: System Operation ............................................................ 30
Keyless Entry: Transmitter ........................................................................ 32
Keyless Entry: Security Indicator ............................................................. 33
Keyless Entry: Control Module/Receiver ................................................. 34
Keyless Entry: Key Coding Process ........................................................ 36
Immobilizer: Introduction .......................................................................... 37
Immobilizer: System Description ............................................................. 38
Immobilizer: Control Unit ......................................................................... 40 EL-1
Immobilizer: LED and Serial Data ........................................................... 41
Immobilizer: ECM .................................................................................... 42
Immobilizer: Immobilization ..................................................................... 44
Immobilizer: DLC Mode and VIN Code .................................................... 45
Immobilizer: Key Coding Procedure ........................................................ 46
Body Wiring ............................................................................................. 47
Electrical: Lab 1 ....................................................................................... 58
Electrical: Lab 2 ....................................................................................... 59
Electrical: Lab 3 ....................................................................................... 60
Electrical: Lab 4 ....................................................................................... 62
Electrical: Test Questions ......................................................................... 63
rev 02
7-4
M-Car:
Electrical
Instructor Guide
rev 02
Supplemental Restraints System (SRS) 7-5
M-Car:
Electrical
The supplemental restraints system (SRS) is a system of safety devices used
in conjunction with the seat belts. The driver and the passengers must
fasten their seat belts and adjust them for proper safety. Instructor Guide
The SRS is designed to protect the driver and the front seat passenger in the
event of a significant frontal impact to the vehicle. The airbag would be
deployed if the crash force is applied within 30 degrees right or left of the
vehicle’s centerline.
The SRS is comprised of:
• Driver Side Airbag Module (45L/1.6 ft3)
• Passenger Side Airbag Module (83L/2.9 ft3)
• Sensing and Diagnostic Module
• Steering Wheel Coil Module
• Wiring Harness
• SRS Malfunction Warning Lamp
An electronic accelerometer continuously measures the vehicle’s acceleration
and deceleration and delivers this signal to a microprocessor. Sophisticated
crash signal processing algorithms in the microprocessor determine whether
deployment is needed or not. If deployment is needed, the microprocessor
activates the firing circuits. If, at the same time, the electromechanical safing
sensor is closed, current is sent to the initiator. EL-2
rev 02
7-6 SRS System: Airbag Deployment Condition
M-Car:
Electrical
Instructor Guide
Above 25 km/h
Above 25 km/h Above 25 km/h
Stop Above Double

Speed (50 km/h)
EL-3 1. Above 25 km/h speed

2. Above both of cars 25 km/h speed
3. Above 50 km/h speed
4. On Collision with up to left and right 30º angles
rev 02
SRS System: Deployment Time Table 7-7
M-Car:
Electrical
Reference for Deployment Timetable
Instructor Guide
Accident
Sensing
Ignotion
Inflating of the Airbag
The Airbag is
completely inflated
The Driver moves
foorward
Head and upper body

dives into the Airbag EL-4
The gas leaves the
Airbag through the
rear side.
The gas has left the

Airbag completely.
The driver is now sitting
in normal Position.
After about 200ms the
deployment and
inflation is finished.
rev 02
7-8 SRS System: Electronic Sensing
M-Car:
Electrical
An electronic accelerometer continuously measures the vehicle’s acceleration
and deceleration and delivers this signal to the microprocessor.
Instructor Guide Sophisticated crash signal processing algorithms in the microprocessor
determine whether deployment is needed or not. When deployment is
needed, the micro-processor activates the firing circuits. If, at the same time,
the electromechanical safing sensor closes, current flows to the inflator and
deployment takes place.
Accident Sensing Barrier Run Over Signal
Accident Signal
Diagram
Accident
Strong Delay
EL-5
rev 02
SRS System: General Precautions 7-9
M-Car:
Electrical
The supplemental restraints system (SRS) warning lamp must light when the
ignition is switched ON, and then turn OFF after approximately 4 seconds.
Instructor Guide
There is a fault in the air-bag system if:
• The warning lamp does not turn OFF
• The warning lamp lights while the vehicle is in operation.
If the warning lamp indicates a fault in the airbag system, assume that the
SRS system is not functional.
Caution: Failure to follow all service procedures in the correct sequence can
cause the airbag system to deploy unexpectedly and possibly cause serious
injury
Only trained personnel authorized service dealerships may service the air-bag
system.
Never attempt to disassemble, repair, or reuse the:
• Air-bag modules.
• Steering wheel coil module
• Sensing and diagnostic module
• Wiring harness
When making SRS repairs:

• Inspect any SRS before it is installed
• Use only new parts
• Do not install used SRS parts from other vehicles
• Do not install any part that has been dropped or that has dents, cracks,
or other defects.
rev 02
7-10 SRS System: Components
M-Car:
Electrical
Composition
Instructor Guide
EL-6
1. Air-Bag Module (Driver Side)

2. Steering Wheel
3. Steering Wheel Coil Module
4. Wiring Harness
5. Air-Bag Module (Passenger Side)
6. SDM (Sensing and Diagnostic Module)
rev 02
SRS System: Components 7-11
M-Car:
Electrical
Driver Airbag Module
Instructor Guide
Cover
Cushion
Retainer Ring Assembly
EL-7
Housing
Inflator Assembly
Caution: When handling an airbag module, always keep the top of the unit
facing upward. This leaves room for the module to expand if the module
unexpectedly deploys. Without room for expansion, a module can violently
inflate toward a person or object and can cause injury or vehicle damage.
rev 02
7-12 SRS System: Components
M-Car:
Electrical
Passenger Airbag Module
Instructor Guide
EL-8
Caution: Tampering with the passenger airbag module creates the risk of an
injury from an unexpected deployment. The passenger airbag module should
never be disassembled.
The passenger airbag module is on the passenger side of the instrument
panel. The passenger airbag module contains an igniter charge and a gas
generator to inflate the folded airbag.
rev 02
SRS System: Components 7-13
M-Car:
Electrical
Steering Wheel Coil Module
The steering wheel coil module:
Instructor Guide
It is located on the steering column
• It contains a coil that is the electrical contact between the steering
column wiring harness and the driver airbag module.
• It is part of the circuit for the horn
Note: Turning the steering wheel more than three and one-quarter turns may
damage the steering wheel coil module.
Air-Bag Module Horn Switch

Connector
Steering Wheel Coil Module

4 Screws Steering Colum
EL-9
Connected to Air-Bag Wiring

Connected to IP Wiring
Harness (Air-Bag Module)
Harness (Horn Switch)
Caution: Disassembling the steering wheel coil module can cause injury
and vehicle damage. The steering wheel coil module should never be
disassembled. The module must be replaced if the air-bags have been
deployed.
rev 02
7-14 SRS System: Steering Wheel Coil Module
M-Car:
Electrical
Remove / Replace
To remove and replace the steering wheel coil module it is necessary to check
Instructor Guide the neutral position of the steering wheel coil and steering.
Caution: To check neutral position, turn the steering wheel coil carefully until
you feel a slight resistance, then turn back 3 1/4 turns and align the neutral
marks.
EL-10
Caution: Disconnect the negative battery past for at least 1 minute before
removing any air-bag module. Remove the air-bag module and the steering
wheel coil and store securely before working on the steering system.
rev 02
SRS System: Sensing and Diagnostic Module 7-15
M-Car:
Electrical
The SDM:
• has no user-serviceable parts Instructor Guide
• is on the floor in front of the front console assembly.
• continuously monitors the air bag components.
• records faults which are detected.
• illuminates an alert-warning lamp.
• allows the fault codes to be retrieved with the Scan Tool.
Caution: Disconnect the negative battery post for at least 1 minute before
removing any air-bag module. Remove the air-bag module and the steering
wheel coil and store securely before working on the steering system.
Ground
SDM Connector
SDM
EL-11
SDM
Gear
Shift
Lever
rev 02
7-16 SRS System: Sensing and Diagnostic Module
M-Car:
Electrical
The SDM controls the deployment of the airbag system through the use of
the:
Instructor Guide
• Safing sensor
• Capacitor
• Crash sensor, or accelerometer
Safing Sensor
The safing sensor is a safety device that is comprised of a dual contact and
an electromechanical switch, it:
• Acts independently from other electronic components.
• Keeps the firing circuits for the airbag unarmed under normal driving
conditions
• Allows the airbag to deploy under the required conditions
Capacitor
The capacitor provides reserve power for SDM even if power is shut-off.
Crash Sensor
The crash sensor electronically signals the accelerometer of deceleration of
the vehicle during a frontal impact. The electrical signal is proportional to the
acceleration or deceleration of the vehicle.
rev 02
SRS System: Wiring Harness 7-17
M-Car:
Electrical
Harness / Connector
Connectors for the sensing and diagnostic module have a built-in shorting
bar that will turn on the warning lamp if there is a poor connection at the Instructor Guide
SDM.
As an anti-deployment mechanism, additional shorting bars are in the:
• Connector for the steering wheel coil module at the lower steering
column
• Passenger airbag module connector
• SDM connector
When these connectors are separated, the shorting bars will short circuit any
current that is applied, preventing the current from reaching the airbag
modules.
To Airbag Module
(Passenger side)
To clock Spring
Wiring Harness
Ground
(under the front
console box)
To SDM
rev 02
7-18 SRS System: Air Bag Warning Lamp
M-Car:
Electrical
Instructor Guide
Bulb Check
As soon as operating voltage is applied to the sensing and diagnostic
module (SDM) ignition input, the SDM activates the warning lamp for a bulb
check. The SDM turns the lamp ON for 4 seconds and then the SDM turns
EL-12 the lamp OFF. During the bulb check, the SDM is not ready to detect a crash
or deploy the supplemental inflatable restraints.
Fault Indication
The sensing and diagnostic module records the system’s faults in two
categories:
• Current faults
• Historic faults, which are those that were detected in the past, but are no
longer active.
The Warning Lamp:

• Indicates a fault as soon as it occurs.
• Stays ON, even if a fault is no longer active.
A Scan Tool connected to the DLC Connector:

• Reveals the fault codes
• Receives serial data transmission through terminal “13” (SIRIUS D3) or
terminal “J” (FENIX 5MR) of the DLC connector.
• Receives ground through the terminal “4” (SIRIUS D3) or terminal “A”
(FENIX 5MR) of the DLC connector.
rev 02
SRS System: Diagnostic Fault Codes (DTC) 7-19
M-Car:
Electrical
Fault Code Fault Contents
01 Driver firing circuit, Resistance too high
Instructor Guide
02 Driver firing circuit, Resistance too low
03 Driver firing circuit, Short to ground
04 Driver firing circuit, Short to battery ground
05 Passenger firing circuit, Resistance too high
06 Passenger firing circuit, Resistance too low
07 Passenger firing circuit, Short to ground
08 Passenger firing circuit, Short to battery voltage
09 Driver pretensioner circuit, Resistance too high
10 Driver pretensioner circuit, Resistance too low
11 Driver pretensioner circuit, Short to ground
12 Driver pretensioner circuit, Short to battery voltage
13 Passenger pretentioner circuit, Resistance too high
14 Passenger pretentioner circuit, Resistance too low
15 Passenger pretentioner circuit, Short to ground
16 Passenger pretentioner circuit, Short to battery voltage
17 Connection between driver firing circuit and Passenger firing circuit
18 Connection between driver firing circuit and Driver firing circuit
19 Connection between driver firing circuit and Passenger pretensioner circuit
20 Connection between driver firing circuit and driver pretensioner circuit
21 Connection between passenger firing circuit and Passenger pretensioner circuit
22 Connection between driver pretensioner circuit and Passenger pretensioner circuit
23 Ignition input circuit, Voltage too high
24 Ignition input circuit, Voltage too low
25 Warning lamp failure
31 SDM internal fault
32 SDM crash recorded
rev 02
7-20 SRS System: Diagnosis
M-Car:
Electrical
SRS and Connectors
Instructor Guide Check the continuity between terminal
9 of the sensing and diagnostic
module and terminal J(13) of the data
link connector
• SIRIUS D3: terminal “13”
• FENIX 5MR: terminal “J”
Check the continuity on the

instrument harness side between
J(13) of the data link connector and
terminal 4 of the connector C208.
EL-13
Measure the wiring harness for

continuity of the driver side airbag
module circuit.
rev 02
SRS System: Diagnosis 7-21
M-Car:
Electrical
SRS Harness and Connectors
Check the continuity of the driver Instructor Guide
airbag circuit on the sensing and
diagnostic module (SDM) side of the
steering wheel coil module connector.
Check the driver airbag circuit for a

short to ground with the sensing and
diagnostic module disconnected.
EL-14
Check the driver airbag circuit for a

short to voltage.
rev 02
M-Car:
Electrical
Instructor Guide Check the steering wheel coil module
connector for a short to voltage on the
sensing and diagnostic module side.
Check the passenger air bag circuit

continuity on the sensing and
diagnostic module side of the
connector.
EL-15
Check the passenger airbag circuit for

a short to ground.
rev 02
M-Car:
Electrical
Check the passenger airbag circuit for Instructor Guide
a short to power.
Check the sensing and diagnostic

module voltage supply at the terminal
5.
EL-16
Check the voltage supply on the

instrument harness side at terminal 2
of the connector C208.
rev 02
M-Car:
Electrical
Instructor Guide Check for a short to ground on the
sensing and diagnostic module side of
the supplemental inflatable restraints
harness at terminal 3 of the connector
C208.
Check for a short to ground in the

instrument harness on the instrument
harness side at terminal 3 of the
connector C208.
EL-17
Check the voltage of the warning lamp

circuit on the instrument harness side
at terminal 3 of the connector C208.
rev 02
M-Car:
Electrical
Check the driver seat belt pretensioner Instructor Guide
circuit continuity on the sensing and
diagnostic module side of the
connector.
Check the driver seat belt

pretensioner circuit for a short to
ground.
EL-18
Check the driver seat belt pretensioner

circuit for a short to voltage.
rev 02
M-Car:
Electrical
Instructor Guide Check the passenger seat belt
pretensioner circuit continuity on the
sensing and diagnostic module side of
the connector.
Check the passenger seat belt

ground.
EL-19
Check the passenger seat belt

voltage.
rev 02
SRS System: Circuit Diagram 7-27
M-Car:
Sirius D3
Electrical
Fenix 5MR
Instructor Guide
A2 Cluster
Air Air-bag
Bag Warming
Lamp
Air-Bag Control Unit (SDM)
Crash Sensor
Safing
Sensor
Contact
Coil
EL-20
Driver Passenger Driver Passenger

Air-Bag Air-Bag Pretensioner
Module Module
rev 02
7-28 Keyless Entry: Introduction
M-Car:
Electrical
The remote keyless entry and anti-theft system can perform the following
functions:
Instructor Guide
• Remotely lock and unlock vehicle doors with a hand-held high frequency
transmitter
• Sense an intrusion into the vehicle through the doors, the trunk or the
hood
• Activate a warning signal for the intrusion
• Help the driver locate the vehicle in a parking area
• Automatically re-lock the doors if a door or the tailgate is not opened
within 30sec after the vehicle has been unlocked by remote keyless entry
• Communicate serial data to the TECH-2 to help diagnose system faults
• Sense motion inside the vehicle, if it is equipped with the optional
ultrasonic motion detector.
The remote keyless entry system consists of the following components:
• Keyless entry and anti-theft module/receiver

• Hand-held transmitter, which is integrated into the ignition key.
• SECURITY indicator
• Tailgate/Trunk or key cylinder switch
• Tailgate/Trunk tamper switch
• Driver & Co-driver key cylinder switches
• Door ajar switches
• Door locking relay
• Turn signal lamps
• Siren
• Hood ajar switch
• Key reminder
• DLC
rev 02
FENIX 5MR
Hot at All Hot in Run SIRIUS D3
Times and Start
Engine I/P
Fuse Fuse
Block Block
RED
BRN
RED
Central YEL/ Data Link Left Turn Right Turn
I/P Connector Signal Signal
Door Lock RED
Fuse ORN Relay (DLC) Lamp Lamp
Block
Siren
ORN RED/
LT YEL/
YEL/ YEL DK BLU/
Blu/ DK BLU PPL DK BLU
WHT RED YEL
ORN
Keyless
Battery Lock Unlock Ignition
Entery
Feed Feed
Control
Module/
Receiver
Keyless Entry: System Diagram
YEL RED/ PNK/BLK WHT

Room
Anti Theft DK BLU Lamp
BLK Status
Indicator PNK/BLK WHT WHT
RED/ WHT
BLK DK BLU WHT (W/Chime Bell)
PNK/BLK WHT WHT WHT
(W/O
Chime Diode
Hood Tailgate
Open Bell)
Switch WHT/ WHT/
Switch
Driver BLK BLK
BLK Door Co-driver Left Rear Right Rear
Open WHT/ Door Door Door
BLK BLK Switch BLK Open Open
Open
Switch Switch Switch
Chime
Bell
7-29
M-Car:
Electrical
EL-21
Instructor Guide
rev 02
7-30 Keyless Entry: System Operation
M-Car:
Electrical
1. Arming
1. Hood closed
Instructor Guide
2. Trunk/Tail gate closed
3. All doors closed
4. Ignition key not inserted in the key cylinder
5. “Lock” button of the transmitter is pressed.
When the system enters the armed mode, the hazard lamps will blink, the
siren or horn will sound briefly one time. The security indicator will blink all
the time.
2. Alarm Tripped
When in armed mode if:
1. Any door is opened
2. The Hood is opened
3. The Trunk/Tail gate is opened
4. The Ignition is turned ON
When the alarm is tripped, the hazard lamps will blink and the siren or horn
will sound for 28 secs. (Europe: 28 sec alarm - 8 times with 5 sec intervals)
3. Disarming
When in armed mode,
1. “Unlock” button or transmitter is pressed
The system enters the disarmed mode, the parking lamps will blink
twice, and the security indicator will go OFF.
2. When the ignition key open the front doors or the trunk/tail gate the
system will enter the disarmed mode, and the security
indicator will go OFF.
4. AlarmOff
When in the alarm mode,
1. “Lock” button of the transmitter is pressed
The alarm is disabled, if the arming conditions are fulfilled, the system
enters the armed mode.
2. “Unlock” button of the transmitter is pressed
The alarm is disabled, the parking lamps will blink twice, and the
security indicator will go OFF.
3. If the front doors or the Trunk/Tail gate is opened with the ignition key,
the alarm is disabed, and the security indicator will go OFF.
rev 02
Keyless Entry: System Operation 7-31
M-Car:
5. Key-In Condition Electrical
Locking, unlocking, arming or disarming will not operate if the lock or

unlock button is pressed while the ignition key is inserted in the key Instructor Guide
cylinder.
6. Vehicle Locator
If the vehicle is unlocked with the remote control, the turn signal lamps
will flash twice to indicate operation completed and vehicle location.
7. Safety Locking
If the doors are unlocked by the transmitter while the system is in the
armed mode, the doors are automatically re-locked and the system re-
armed unless one of the following events occur within 30 sec:
• Any door is opened
• The ignition key is inserted
• The tailgate/trunk is opened
• The hood is opened
The parking lamps will blink and the siren will sound briefly once when
the system rearms.
8. Fault or Intrusion Indication

When the unlock button on the transmitter is pressed, the parking lamps
will flash to indicate the system condition.
1. Normal Condition: If there has not been an intrusion, and no fault
has been detected, the control module/receiver will signal a normal
condition. The parking lamps will flash twice with a 0.5 sec on/off
interval.
2. Intrusion Indication: If there has been an intrusion since the last time
the lock switch was pressed. The parking lamps will flash twice with
a 1 sec on/ 0.5 sec off interval. Intrusion information in the control
module/receiver will be erased during the next ignition cycle.
9. Trunk Rearming
If the trunk is opened with the key while the vehicles is in the armed
mode, the vehicle will go to the disarmed mode. The vehicle returns to
the rearmed mode after the trunk is closed again. If any door is opened
without the key, or if the hood is opened while in the rearmed mode, the
vehicle detects the intrusion and activates the alarm.
rev 02
7-32 Keyless Entry: Transmitter
M-Car:
Electrical
The hand-held transmitter locks or unlocks the vehicle doors by sending radio
signals to the receiver. The transmitter is an integrated part of the ignition key.
Instructor Guide The effective range of the transmitter is 6m, depending on whether the path of
the radio signal is blocked by other objects. The transmitter has both lock and
unlock buttons and a replaceable battery designed to last two years. Key
coding is possible for up to 5 keys (or transmitters) with the Scan Tool.
Re-synchronization
The keyless entry system employs the rolling code system.
If the transmitter is operated out of range more than 16 times, the keyless
entry system will not operate because the receiver loses code
synchronization.
The system is automatically re-synchronized if the transmitter is operated again
within range. However, if the transmitter is operated out of range more than
32,768 times, the transmitter should be re-coded by the Scan Tool.
Battery CR1620, 1 EA
Operating Voltage 3V
EL-22
Frequency 315 MHz
Battery Life Cycle 2 years in case the transmitter used 10 times a day
Operating Range Minimum 6m
Available Transmitters 5 EA
k
Loc
Lock
ck
Unlo
Unlock
LED
rev 02
Keyless Entry: Security Indicator 7-33
M-Car:
Electrical
The security indicator is located in the center console. Once the system
enters the armed mode, the indicator will flash. The indicator cycles by
turning on for 0.125 sec. and off 0.875 sec. until the control module/ receiver Instructor Guide
is disarmed.
Indicator
EL-23
rev 02
7-34 Keyless Entry: Control Module/Receiver
M-Car:
Electrical
The remote keyless entry control module/receiver is located under the
I. P.. The control module/receiver activates the alarm if an intrusion is
Instructor Guide detected. The control module/receiver also has a self-diagnostic function. In
order to display trouble codes, the Scan Tool must be connected to the Data
Link Connector.
The control module/receiver will not communicate with transmitters from
other vehicles because there are over four billion possible electronic
password combinations and the passwords can not be duplicated. The
control module/receiver has an attached antenna to detect signals from the
transmitter.
rev 02
Keyless Entry: Control Module/Receiver 7-35
M-Car:
Electrical
Instructor Guide
Pin No Color Functions Remarks

1 GW Siren Control
2 B GND
3 Not used
4 L Trunk Tamper Switch
5 OrB Trunk Open Switch
6 Not used
7 BrB Hood Open Switch
8 GW Door Open Switch
9 Gr Door Lock Position Monitoring
10 GrG Door Locking Relay Locking Control EL-24
11 YG Door Locking Relay Unlocking Control
12 L Driver Door Tamper Switch
13 L RH Parking Lamp Control
14 Not used
15 P IGN+
16 Not used
17 BW Serial Data (DLC "8")
18 Lg Key-In Sigal
19 Y Security Indicator Control
20 L Passenger Door Tamper Switch
21 Not used
22 Not used
23 Not used
24 Not used
25 Or BAT+ (POWER)
26 Sb RH Parking Lamp Control
rev 02
7-36 Keyless Entry: Key Coding Process
M-Car:
Electrical
If a transmitter is lost or damaged, the control module/receiver will have to be
re-programmed to communicate with a new transmitter. The passwords
Instructor Guide recorded in the control module/receiver will not be deleted when power is off
in the control module/receiver.
The control module/receiver is able to record five passwords (five
transmitters).
The following method is used to record new passwords in the control
module/receiver.
1. Connect the Scan Tool to the DLC connector

2. Enter the “coding system” menu
3. Select the “coding only” menu
4. Enter a code “ 0 0 0 0” (This code should be kept secret)
5. Select the “keyless entry”
6. Select the transmitter coding
7. To process coding, “Press any button of the first transmitter”,
To quit the coding process, “Press ESC button”
8. “Press any button of the second transmitter” message will be shown.
9. If the second transmitter is needed, follow 6th step, otherwise, press
ESC.
10. Coding successful message will be shown.
11. Confirm its operation.
NOTE: During the coding process, previous coded keys are deleted
automatically.
rev 02
Immobilizer: Introduction 7-37
M-Car:
Electrical
The purpose of the immobilizer system is to provide additional theft
deterrence to the vehicle and to prevent it from being stolen or driven by
unauthorized users. Instructor Guide
An ignition key with integrated transponder does the verification of the user
authorization.
An external LED displays the immobilizer status which is communicated
between the immobilizer and the ECM in encoded data for additional theft
deterrence. This encoded data is comprised of a mixture of random data and
two types of fixed code.
• A vehicle model identification number: MIN

• A vehicle specific identification number: VIN
Note: The immobilizer VIN is comprised of random data, it is NOT the vehicle
Identification Number
The MIN is known from the first initialization of the system.
The VIN is programmed by ICU on special order during key coding
Random data is computed at each key transition.

All the immobilization communication between the ECM and ICU is made on
the K-line (K line: DLC ‘6’).
Due to the programming of the specific VIN, both ICU and ECM can stay in 3
stable modes:
• Virgin mode (VIN not programmed)

• Learned mode (VIN programmed)
• Neutral mode (Ready for a new VIN programming)
If a valid key is used, the ECM transmits a release message and a valid key
status to the immobilizer. If an invalid key is used, the ECM disables the fuel
injector circuit and sets a DTC. These conditions are maintained until the
ignition is switched off.
An ECM without an immobilizer control unit cannot be interchanged with an
ECM that has an immobilizer control system. The Immobilizer control unit and
ECM must have matching ID codes. ID coding and key coding are
accomplished by using the TECH-2.
rev 02
7-38 Immobilizer: System Description
M-Car:
Electrical
The Immobilizer system consists of
• A maximum or 5 ignition keys with integrated transponders
Instructor Guide
• A toroidal coil (Detection coil) mounted at the ignition lock for energizing
and reading the transponder.
• The Immobilizer control unit(ICU) with:
- power supply
- ignition input circuit
- transponder modulation and demodulation unit
- EEPROM
- electronic driver for the external status LED
- serial data link hardware
• The external status LED for displaying the Immobilizer status
• The serial data link between Immobilizer and ECM
• ECM
rev 02
Immobilizer: System Description 7-39
M-Car:
Transponder Electrical
Each valid ignition key has an internal transponder, which is a read /write Instructor Guide
transponder.
The transponder contains a crypto-algorithm with 96 bits of user
configurable secret-key memory. It is contained in EEPROM and transmits
data to the ICU by modulating the amplitude of an electromagnetic field. It
receives data and commands similarly.
Toroidal Coil (Detection Coil)

The toroidal coil is mounted on the ignition lock in front of the key barrel. It is
integrated to the ICU housing package with the body of the coil to improve
the performance of transponder reading of the ECM.
The toroidal coil and receiving coil inside the transponder create a
transformer. During the reading process the coil induces energy into the
transponder. The transponder charges the field and generates an amplitude
modulated signal with the manchester coded data. This charge of the field is
demodulated inside the Immobilizer. The Immobilizer contains the coil driver
hardware for direct connection of the toroidal coil.
rev 02
7-40 Immobilizer: Control Unit
M-Car:
Electrical
The functions of the Immobilizer System are shared by the ICU and the ECM.
Instructor Guide
The tasks of the Immobilizer Electronic Control unit are:
• Reading of the input information ‘ ignition ON/OFF’
• Controlling the status LED
• Controlling the transponder read/write process (modulation,
demodulation, decoding, comparison of the read code with the code of
the valid keys).
• Communication with the ECM after ignition ON (receiving of the ECM-
request and transmission of release messages).
• Special functions for calculation and handling of the VIN-code.
The Immobilizer uses a random generator to calculate the VIN code. The VIN
code is transmitted from the Immobilizer in the release message for an
authorized key only. It is not possible to receive the system VIN code from an
unauthorized key.
If the ECM is in virgin or neutral mode the ECM learns the system VIN code
automatically after receiving the first release response message. To get a
synchronized Immobilizer system (same VIN-code in Immobilizer, ECM, and
authorized key), DLC test equipment must be used. This test equipment is
restricted to authorized persons only.
Main functions of the DLC-test equipment are key coding procedures, VIN-
code handling and the support for system test functions.
rev 02
Immobilizer: LED and Serial Data 7-41
M-Car:
LED Electrical
An external LED displays the Immobilizer system status. The Immobilizer
contains the LED driver hardware for direct connection to the LED. Instructor Guide
Status LED System Staus Note
OFF Immobilizer active - Ignition OFF
Blinking (f = 1 Hz) - Invalid key detected

Immobilizer active
Duty cycle 7 : 1 - Ignition ON
- Valid key detected

OFF Immobilizer inactive
- Ignition ON
- VIN-code is different between ICU and

Blinking (f = 1 Hz)
Immobilizer active ECM in learned state
Duty cycle 5 : 5
- Ignitin ON
- Transponder reading error

ON Immobilizer active
- Ignition ON
Blinking (f = 2 Hz) - Reader exciter ASIC error

Duty cycle 5 : 5
Immobilizer active
- Ignition OFF
EL-25
Serial Data Link

Serial data can be exchanged between a Scan Tool, ECM and the
Immobilizer control unit.
Serial Data
rev 02
7-42 Immobilizer: ECM
M-Car:
Electrical
• ECM in Virgin Mode
In this mode, the ECM knows only the model vehicle identifier code.
Instructor Guide
The VIN code is stored in non-volatile memory
The engine can be locked/unlocked. ECM requests the VIN number from
the ICU. As soon as the ECM receives two correct consecutive
communication frames with the same VIN code the ECM retains it. The
VIN code will be stored in non-volatile memory instead of 0FFFFh at the
end of power latch phase.
• ECM in Learned Mode

In learned mode the ECM checks for the correct encoding of the ICU on
every communication. If the correct code is not received, the vehicle is
immobilized.
• ECM in Neutral Mode

This mode is a special intermediate mode, used for ICU replacement or
immobilizer option installation. The ECM requests the VIN number from
the ICU. As soon as the ECM receives two correct consecutive
communication frames with the same VIN code, the ECM retains it. The
VIN code will be stored in non-volatile memory and the ECM enters into
“learned” mode.
rev 02
Immobilizer: ECM 7-43
M-Car:
Electrical
• After starting the ECM will control the engine in a normal way for starting
and running while waiting for a valid release response message from the
Immobilizer. Instructor Guide
1. After receiving a response message including the information ‘ICU in
learned mode’ and the correct system VIN-code …
- The ECM enters the release state, which allows the engine to
continue running.
2. After receiving a response message including the information ‘ICU in
learned mode’ and a wrong system VIN-code…
- The ECM does not send a new request and enters the blocked
state, which causes the activation of the immobilization of the
engine.
3. If the ECM doesn’t receive a response message within a defined
release time period or the ECM receives a no release answer…
- The ECM enters the blocked state, which causes the activation
of the immobilization of the engine.
• The inactive state of the Immobilizer (valid key/invalid key) ends with
turning off the ignition.
• The immobilizing state of the ECM (released/blocked) ends with turning
off the ignition or with removing the battery voltage.
rev 02
7-44 Immobilizer: Immobilization
M-Car:
Electrical
In the Immobilizer active mode (engine OFF, IG key OFF) the status LED will
blink in mode A. When ignition is turned ON, the system activates and tries to
Instructor Guide read the transponder. If a valid key is detected, a release message
communication with the ECM takes place. The status LED displays the
Immobilizer message ‘valid key’.
Learned Mode
Correct VIN-Code
Release
Valid Message
Key Communication
Inactive Mode
Learned Mode LED Off
Learned Mode
Release Incorrect VIN-Code
Valid Message
Key Communication
Active Mode
No Release LED Blinking
EL-26 Answer (5:5)
Learned Mode
Incorrect VIN-Code
Release
Valid Message
Key Communication Active Mode
LED Blinking
No Release
(7:1)
Answer
When the ignition is turned off (ignition OFF detection similar to the ECM
ignition OFF detection), the Immobilizer changes to the active mode. The
status LED will blink in Mode A.
rev 02
Immobilizer: DLC Mode and VIN Code 7-45
M-Car:
DLC Mode Electrical
When the ignition is on, a Scan Tool can switch the immobilizer control unit
to the DLC mode for diagnostics, key coding and ID coding. Instructor Guide
The status LED is turned off during DLC-mode

The Immobilizer will answer all correct messages, which are defined as
Immobilizer messages
VIN Code Handling

One of 65,535 VIN codes is stored in the immobilizer EEPROM. When the
Immobilizer control unit calculates a new VIN code, the ECM VIN code should
be reset to synchronize it’s VIN with the immobilizer control unit.
During diagnostic procedures, the VIN code can be read for comparison with
the ECM VIN code by using the Scan Tool’s “Read immobilizer control unit
VIN code” command.
rev 02
7-46 Immobilizer: Key Coding Procedure
M-Car:
Electrical
1. Turn the ignition off
2. Connect the Scan Tool
Instructor Guide
3. Enter the “coding system” menu
4. Select the “coding only” menu
5. Enter a secret code “ 0 0 0 0”
6. Select the “Immobilizer”
7. Perform key coding function
8. Follow the instructions
A. Key OFF
B. Key ON with the second key
C. Press the “Enter” key
D. Select “NO” if additional third key is not desired
E. Key off for 3 seconds
F. Key on for 2 seconds
G. Repeat 5) and 6) three times
H. Hit the “Enter” key
I. Confirm the key coding with the diagnosis function.
NOTE: If installation and key coding of a new ICU is necessary, key ON/
OFF transition must be performed three times with the same key before
performing the key coding.
New ICUs (never installed in a vehicle before) have a special function called
‘Auto Key Coding’ for the convenience in car manufacturing key coding lines.
This function must be disabled before performing the key coding with Scan
Tool. To accomplish this perform the key ON/OFF transition three times with
same key.
New ICUs can be distinguished from others if the LED blinks when the ICU is
installed.
rev 02
Body Wiring 7-47
M-Car:
Electrical
Front Harness
Instructor Guide
1. CCP Solenoid 11. FRT, Fog Lamp LH

2. C101 12. Engine Cooling Fan
3. C205 13. Hood Switch
4. C202 14. Dual Pressure Switch
5. C206 15. FRT, Fog Lamp RH
6. Left Front Wheel Sensor 16. Power Steering Oil Pressure
7. C102 Switch
8. Head Lamp LH 17. G102
9. Horn 18. Head Lamp RH
10. G101 19. Right Front Wheel Sensor
20. ABS Control Unit
rev 02
7-48 Body Wiring
M-Car:
Electrical
Engine Harness (Sirius D3)
Instructor Guide
1. IAC
2. EI System 11. Battery B+
3. TP Sensor 12. EEGR
4. CMP Sensor 13. Injector 1, 2, 3
5. Battery B+ 14. Generator
6. To ECM 15. Generator B+
7. Reverse Lamp Switch 16. Starty Motor
8. CKP Sensor 17. G103
9. O@ Sensor 18. KS
rev 02 10. ECT Sensor 19. To ECM
Body Wiring 7-49
M-Car:
Electrical
Engine Harnes (Fenix 5NR)
Instructor Guide
1. Idle Air Control Valve (IAC) 9. Idle Air Control (IAC)

2. EGR (Unleaded Only) 10. Throttle Position Sensor (TP
3. TP Sensor Sensor)
4. Manifold Air Temperature 11. Exhaust Gas Recirculation
Sensor (IAT) Solenoid (EGR)
5. Optical Sensor (Engine Speed 12. Knock Sensor
Sensor) 13. Generator B+
6. Reverse Lamp Switch 14. G103
7. O2 Sensor 15. Manifold Air Temperature
8. Coolant Temperature Sensor Sensor (IAT)
(ECT) 16. Optical Sensor (Engine Speed
Sensor) rev 02
7-50 Body Wiring
M-Car:
Electrical
Instrument Harness (Left Hand Drive)
Instructor Guide
1. G201
2. C201 12. Front or Rear Fog 22. Ignition Switch23.
3. C205 Lamp Switch Immobilizer
4. C206 13. Cluster Connector 24. Stop Lamp Switch
5. C204 14. Wiper Switch 25. Anti-Theft Control Unit
6. C203 15. Light Switch 26. C208
7. I/P Fuse Block and 16. Headlamp 27. Cigar Lighter
Relays Leveling Switch 28. Audio
8. Hazard Switch 17. C205 29. Evaporator Thermistor
9. Immobilixer Display 18. C206 30. Blower Resistor
10. Blower Motor 19. C201 31. Blower Motor
Switch 20. C203 32. DLC Connector
rev 02
11. Rear Defroster 21. C204 33. CDL Relay
Switch
Body Wiring 7-51
M-Car:
Electrical
Instrument Harness (Right Hand Drive)
Instructor Guide
1. C201 14. DLC Connecotor

2. G201 15. Blower Motor
3. I/P Fuse Block and Relays 16. Blower Resistor
4. C204 17. Evaporator Thermistor
5. C203 18. Audio
6. Cluster Connector 19. Cigar Lighter
7. Front or Rear Fog Lamp Switch 20. C208
8. Hazard Switch 21. Stop Lamp Switch
9. Immobilizer Display 22. Ignition Switch
10. Blower Motor Switch 23. Dimmer Control Switch
11. Rear Defroster Switch 24. Headlamp Leveling Switch
12. C203 25. C204
13. C205 26. C202 rev 02
7-52 Body Wiring
M-Car:
Electrical
Airbag Harness
Instructor Guide
1. Passenger Air-Bag Module

2. DLC Connector
3. Sensing and Diagnostic Module (SDM)
4. G302
5. C208
6. Contact Coil
7. C208
rev 02
Body Wiring 7-53
M-Car:
Electrical
Body Harness
Instructor Guide
1. Right Rear Speaker 9. C351

2. Right Tail Lamp 10. C352 (LHD)
3. G402 11. Parking Brake Switch
4. Fuel Pump 12. G301
5. Left Rear Wheel Speed Sensor 13. C362 (RHD)
6. C371 14. C361
7. Driver Door Contact Switch 15. Passenger Door Contact
8. Seat Belt Switch Switch
16. C381
rev 02
7-54 Body Wiring
M-Car:
Electrical
Body Harness
Instructor Guide
1. C204
2. C205
3. C206
4. C203
5. C202
6. C201
7. Left Tail Lamp
8. G401
9. Left Rear Speaker
10. C401
11. C402
rev 02
Body Wiring 7-55
M-Car:
Electrical
Front Door Harness
Instructor Guide
1. Power Window Motor

2. OSRV Switch
3. C351 (LHD)
C352 (LHD)
C361 (RHD)
C362 (RHD)
4. Front Speaker
5. Door Lock Actuator
rev 02
7-56 Body Wiring
M-Car:
Electrical
Rear Door Harness
Instructor Guide
1. Rear Power Window Switch

2. Rear Door Lock Actuator
3. C371 (LH)
C381 (RH)
rev 02
Body Wiring 7-57
M-Car:
Electrical
Tailgate Harness
Instructor Guide
1. C402 8. G403
2. Rear Defroster Connector 9. G404
3. CHMSL
4. Rear Wiper Motor
5. License Lamp
6. C403
7. C401 rev 02
M-Car
HVAC
Instructor Guide
M-Car:
HVAC
Schematic of Air Conditioning ................................................................... 5
Instructor Guide
A/C Specification ....................................................................................... 6
Control Panel ............................................................................................ 7
Compressor ............................................................................................... 8
Cooling Fan ............................................................................................... 9
Condenser, Receiver-Drier, Dual Cut Switch .......................................... 10
Evaporator / Thermistor ........................................................................... 11
Expansion Valve / Heater Core ............................................................... 12
Schematic and Routing Diagram: A/C .................................................... 13
Schematic and Routing Diagram: Non-A/C ............................................ 14
HVAC: Lab 1 ............................................................................................ 15
HVAC: Test Questions ............................................................................. 16
HV-1
rev 02
8-4
M-Car:
HVAC
Instructor Guide
rev 02
Schematic of Air Conditioning 8-5
M-Car:
HVAC
A/C System
Instructor Guide
1. Mode Control Door

2. Heater Core
3. Recirculating Air Control Door
4. Temperature Control Door HV-2
5. Evaporator Core
6. Blower Motor
A/C Air Flow
1. Condenser 4. Compressor
2. Expansion Valve 5. Receiver Dryer
3. Evaporator
rev 02
8-6 A/C Specification
M-Car:
HVAC
A/C System
Instructor Guide
Application Description
Compressor SP - 10.4PK
Receiver Dryer AL R/ DRYER
Type R-134a System

Refrigerant
Capacity 500g (1 lb)
Type PAG OIL

Refrigerant oil in A/C System
Capacity 150 cc (5 oz)
A/C cooling capacity 5500 kcal/h (21,825 Bru)
Refrigerant pressure:Engine idle,

o
fresh air( 30 C/86°) Low pressure side 200 (kPa) (29 psi)
o o
Ambient Temp (25 C-35 C)
Temperature to full cold (77°- High pressure
1500 kPa (217 psi)
95°F) side
rev 02
Control Panel 8-7
M-Car:
HVAC
Instructor Guide
1. Temperature Control Switch

2. Air Distribution Switch
3. Fan Control Switch
4. Air Conditioning Switch
5. Air Intake Switch
6. Defrost Switch HV-3
1. Temperature Control
Cable
2. Mode Control Cable
3. Recirculation / fresh
air door cable
switch
rev 02
8-8 Compressor
M-Car:
HVAC
Instructor Guide
Compressor Operation
Classification Requirement Operation
HV-4 Blower Motor Over 1step
A/C Switch Switch is ON

o
OFF 115 C (239°F) or more
CTS
o
ON 112 C (234°F) or less
Evaporative o
OFF 1 C (34°F) or less
Thermistor
o
Temperature ON 2.5 C (34°F) or more
OFF Less than 640 or More than 6600

RPM
ON More than 990 or Less than 5400
2
Low Pressure OFF 2.1 kg/cm (30 psi)
Dual Cut Off Switch
2
High Pressure OFF 32 kg/cm (455 psi )
rev 02
Cooling Fan 8-9
M-Car:
HVAC
The cooling fans are mounted
behind the radiator in the engine Instructor Guide
compartment. The electric
cooling fans increase the flow of
air across the radiator fan and
across the condenser on A/C
(air conditioner)-equipped
vehicles. This helps to speed
cooling when the vehicle is at
idle or moving at low speed.
1. Fan Motor
2. Fan
Cooling Fan Operation
Cooling Fan Coolant Temperature Remarks
ON 93°C (200° F) - CTS Faulty

Low Speed - Jumping A & C Terminal of
OFF 90°C (194° F) ALDL
HV-5
ON 100°C (212° F)
High Speed - A/C Switch ON
OFF 97°C (207° F)
rev 02
8-10 Condenser, Receiver-Drier, Dual Cut Switch
M-Car:
HVAC
Condenser
Instructor Guide The condenser assembly in front of the radiator consists of coils that carry
the refrigerant and cooling fins that provide for the rapid transfer of heat. As
air passes through the cooling fins, the high-pressure refrigerant vapor cools
and condenses into a liquid.
Receiver Dryer
HV-6 The sealed receiver-dryer assembly is connected to the condenser outlet
tube. It acts as a refrigerant storing container, receiving high-pressure liquid
refrigerant from the condenser. At the bottom of the receiver dryer is the
desiccant* that acts as a drying agent for the moisture that may have entered
the system. The receiver dryer is replaceable as an assembly only.
Dual Cut-off Switch

The dual cut-off switch controls compressor operation when the cycling
refrigerant pressure drops too low or surges too high.
1. Dual Cut-off Switch
rev 02
* Desiccant: A substance that removes water
Evaporator / Thermistor 8-11
M-Car:
HVAC
Evaporator
The evaporator is a device that cools and dehumidifies the air before it enters Instructor Guide
the passenger compartment. High-pressure liquid refrigerant flows through
the expansion valve and becomes a low-pressure gas in the evaporator. The
heat in the air passing through the evaporator core is transferred to the
cooler surface of the core, which cools the air. As the heat is transferred from
the air to the evaporator core surface, moisture in the air condenses on the
outside surface of the evaporator core and is drained off as water.
Evaporator-Thermistor
The evaporator-thermistor is a semiconductor that noticeably changes in
resistance as the temperature changes. When the refrigerant temperature of
the evaporator drops to 0oC (32oF) and below, the evaporator core gets
blocked with frost or ice, reducing the airflow and lowering the cooling
capacity. The thermistor is a sensor that is used to prevent frost or ice from
forming. The thermistor is installed on the evaporator.
HV-7
1. Screw
2. Clamp
3. Screw
4. Upper Cover
5. Lower Cover
6. Thermistor
7. High Pressure Pipe
Line
8. Tape
9. Evaporator Plate
Seal
10. Expansion Valve rev 02
8-12 Expansion Valve / Heater Core
M-Car:
HVAC
The expansion valve is located on the passenger compartment side under
Instructor Guide the IP. The expansion valve can fail in three different positions: open, closed
or restricted.
An expansion valve that fails in the open position will result in a noisy A/C
compressor or no cooling. The cause can be a broken spring, a broken ball
or excessive moisture in the A/C system. If the spring or the ball is found to
be defective, replace the expansion valve. If excessive moisture is found in
the A/C system, recycle the refrigerant.
An expansion valve that fails in the closed position will result in low suction
pressure and no cooling. A failed power dome or excessive moisture may
cause this in the A/C system. If the power dome on the expansion valve is
found to be defective, replace the expansion valve.
If excessive moisture is found in the A/C system, recycle the refrigerant.
A restricted expansion valve will result in low suction pressure and no
cooling. This may be caused by debris in the refrigerant system. If debris is
believed to be the cause, recycle the refrigerant, replace the expansion valve,
and replace the receiver dryer.
Heater Core
HV-8 The heater core heats the air before it enters the passenger compartment.
Engine coolant is circulated through the core to heat the air passing over the
fins of the core.
Heater Core
rev 02
Schematic and Routing Diagram: A/C 8-13
M-Car:
HVAC
Power at Power with Lights Power at Power in Run Instructor Guide
All Times On All Times and Start
Ignition
Relay Engine
Fuse
Block
Main
Relay
A/C
Switch Blower
Resister
A/C
Compressor
Relay
Switch
Ilumination
Lamps
HV-9
Dual
Blower
Pressure
Motor
Switch
A/C A/C Main A/C Eletronic

Compressor Compressor Relay Signal Control
Clutch Relay Control Module
Control (ECM)
rev 02
8-14 Schematic and Routing Diagram: Non-A/C
M-Car:
HVAC
Power at Power in
Run and
Instructor Guide All Times Start
Ignition Engine
Relay Fuse Blower
Block Motor
Resistor
Blower
Switch
Blower
Motor
HV-10
rev 02

Manual de Servicio Chevrolet Matiz 800 y 1L - Spark

Cargado por

Información del documento

Derechos de autor

Formatos disponibles

Compartir este documento

Compartir o incrustar documentos

Opciones para compartir

¿Le pareció útil este documento?

¿Este contenido es inapropiado?

Copyright:

Formatos disponibles

Manual de Servicio Chevrolet Matiz 800 y 1L - Spark

Cargado por

Copyright:

Formatos disponibles

CAPÍTULO 1

Motor 1000cc: Número de motor............................................................. 31

Instructor Guide Vehicle Performance

Maximun speed (km/h) 144 (89.5 mph)

Maximun Power.kw (ps)/rpm 37.5(51.0)/6000(50 hp)

Maximum torque. kg.m

Engine type Overhead Cam L3

Bore(mm) × stroke(mm) 68.5 x 72.0 (2.7in x 2.8 in)

Total displacement (cc) 796 (49 cu in)

Compression ratio 9.3 : 1

Application Unleaded Leaded

Golden : BPR5EY-11 Golden : BPR5EY

Oil Pump Type Rotary (Trochoid)

Oil Filter Type Full Flow

Oil Pan Capacity with Oil Filter 2.7 L (2.9 qts)

Cooling Type Forced Water Circulation

Radiator Type Cross Flow

Water Pump Type Centrifugal

Thermostat Type Pellet Type

Coolant Capacity 3.8 L (4 qts)

Battery 12V-35AH, 275CCA

Fuel Delivery Type MPI

Fuel Pump Type Electric Motor Pump

Fuel Filter Type Cartridge

API SJ Grade SAE 10W-30

3.8 L Water + Ethylene glycol base antifreeze

Key lock cylinder As Required Silicone Lubricant

Clutch linkage pivot points As Required Grease

Parking brake cable As Required Grease

Hood latch assembly As Required Grease

Hood and Door hinges

Weatherstrips As Required Silicone grease

Measuring Valve Clearance

IN 0.15 ± 0.02 / 0.006 ± 0.0007

1. Warm up engine, jump terminals 2. Check ignition timing with

3. Ignition Timing: 10° before TDC 4. If ignition timing needs adjustment,

Alternator 635 / 25"

A/C Belt 735 / 28.9"

Model Part number ID Length Maintenance

851.6 mm I : 40,000 km / 24,800 mi

NOTE: I = Inspection; R = Replacement

2. Align the both marks on

3. Install the timing belt

1. Warm up until normal operating temperature

Application Specification Remarks

Capacity of Oil 2.7 L (2.85 qt) Including Oil Filter

- Normal Condition : Every 10,000 km (6,214 mi)

Engine Oil Pressure Check

- Idle : 1 ± 0.2 kg/cm² (14 psi)

Oil Pressure Switch Tightening Torque 120-160 kg cm (104 - 139 lb/in)

1. Fuel Pressure Regulator 3. Overflow Valve

NOTE: Fuel Pressure = 3.6 - 3.8 kg/cm² (51-54 psi)

“2” Ter “2” Ter

Element: Activated Carbon

1. Evaporative Emissions Canister

Air-Fuel Mixture Temperature (ºC)

Surge Tank Cap

Thermostat Cooling Fan

Cooling Fan Size 320 mm, 14 A (12.6 in)

458 x 295 x 16 (STD) mm

COOLING FAN COOLING FAN

COOLING FAN COOLING FAN

ER-16 Sequential Number

Maximun Power.kw (ps)/rpm 46.5 (63.2) / 5400 (62.4 hp)

Fuel Pressure regulator