Kia Soul Ev 2015 Workshop Service Repair Manual

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General Information
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
General Information
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
General Information
Basic Service Symbols
There are five primary symbols used to complement illustrations. These symbols indicate that particular materials should be applied in each
part during the sevice.
Symbol
Meaning
Do not reuse the part. Replace a new one.
Apply engine oil or transmission oil to the part.
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Apply automatic transmission fluid (ATF) to the part.
Apply grease to the part.
Apply sealant to the part.
General Information
General Service Information
Protection Of The Vehicle
Always be sure to cover fenders, seats, and floor areas before starting work.
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to prevent the
hood from falling and causing possible injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is firmly latched before
driving the vehicle.
Preparation Of Tools And Measuring Equipment
Be sure that all necessary tools and measuring equipment are available before starting work.
Special Tools
Use special tools as needed
Removal Of Parts
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First, find the cause of the problem and then determine whether to remove or disassemble before starting the job.
Disassembly
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not
affect their performance or external appearance.
1. Inspection of parts
Each removed part should be examined carefully for any suspected malfunctions, deformantion, damage and other problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify parts to be replaced from reusable parts.
3. Cleaning parts for reuse
All reusable parts should be carefully and thoroughly cleaned by an appropriate method.
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Parts
When replacing parts, use KIA MOTORS genuine parts.
Replacement
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
Once removed, the following parts should always be replaced with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on their location.
7. Sealant should be applied to gaskets.
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8. Oil should be applied to the moving components of parts.
9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.
Adjustment
Use gauges and testers to correctly adjust the parts according to standard values.
Electrical System
1.
2.
3.
4.
Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
Never pull on the wires when disconnecting connectors.
Locking connectors will click when the connector is secure.
Handle sensors and relays carefully. Be careful not to drop them against other parts.
Rubber Parts And Tubes
Always keep rubber pats and tubing away from gasoline.
Measuring Body Dimensions
1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensions and actual - measurement dimensions are used in this manual.
Dimensions Projected
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1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the reference
dimensions used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the height difference
between two surfaces.
Measuring Actual Dimensions
1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference dimensions when a
tracking gauge is used for measuring.
2. First adjust both probes to the same length (A=A') before measuring.
Check the probes and gauge it self to make sure that there are no loose parts.
Measurement Point
Measurements should be taken at the center of the hole.
Checking Cables And Wires
1.
2.
3.
4.
5.
6.
Check the terminal for tightness.
Check terminals and wires for corrosion from battery electrolyte, etc.
Check terminals and wires for open circuits.
Check wire insulation and coating for damage, cracks and degrading.
Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's body.
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7. Check for incorrect wiring.
8. Check that the wiring is so clamped to prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating or moving parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle body and the engine.
Check Fuses
A blade type fuse test taps are provided to allow checking the fuse itself without removing it from the fuse box. The fuse is good if the test
lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is grounded. (Turn the ignition switch so that
the fuse circuit becomes operative)
Servicing The Electrical System
1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by the
computer will be cleared. Therefore, if necessary, record the diagnostic data before removing the battery cable.
2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other vibrating
parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact
with any of the surrounding parts and then secure the harness using a clamp.
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3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or something
similar in order to protect it from damage.
4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
6. The electronic parts used in the computer, relays, etc. are prone to heat. If there is a need for service operations that may cause the
temperature to exceed 80°C (176°F), remove the electronic parts before handling.
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7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
8. When disconnecting a connector, be sure to grip only the connector, not the wires.
9. Disconnect connector which have catches by pressing in the direction of the arrows as in the illustration.
10. Connect connectors which have lock tabs by insertingthe connectors until they make a clicking sound.
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11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the
connector is a sealed connector, insert the test probe through the hole in the rubber cap until it touches contacts the terminal, being
careful not to damage the insulation of the wires.
12. To avoid overloading the wires, determine the appropriate wire size considering the electrical current load of the optional equipment.
Permissible current
Nominal size
SAE gauge No.
0.3mm²
AWG 22
-
5A
0.5mm²
AWG 20
7A
13A
In engine compartment
Other areas
0.85mm²
AWG 18
9A
17A
1.25mm²
AWG 16
12A
22A
2.0mm²
AWG 14
16A
30A
3.0mm²
AWG 12
21A
40A
5.0mm²
AWG 10
31A
54A
General Information
Identification Numbers
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Identification Number Description
Vehicle Identification Number
1. World Manufacturer Identifier (WMI)
- KNA : Passenger vehicle, MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational Vehicle)
- KNC : Commercial vehicle (Van)
- KND : MPV/SUV/RV (For U.S.A, Canada, Mexico)
- KNH : Van
2. Vehicle line
- J : SOUL
3. Model & Series
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- M : Low grade (L)
- N : Middle-Low grade (GL)
- P : Middle grade (GLS, JSL, TAX)
- R : Middle-High grade (HGS)
4. Body/Cabin type, Gross Vehicle Weight Rating
KNA
- 1 : Limousine
- 2 : Sedan - 2 door
- 3 : Sedan - 3 door
- 4 : Sedan - 4 door
- 5 : Sedan - 5 door
- 6 : Coupe
- 7 : Convertible
- 8 : Wagon
- 9 : Commercial Van
- 0 : Pick-Up
KNC (Commercial vehicle / Van)
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China
- X : Standard Cabin / Semi-Bonnet
- Y : Double Cabin / Bonnet
- Z : Super Cabin / Box
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China
- 2 : Standard Cabin Class-H 4×2
- 3 : Standard Cabin Class-E 4×2 / Semi-Bonnet Class-E 4×2
- 4 : Standard Cabin Class-E 4×4 / Semi-Bonnet Class-E 4×4
- 5 : Standard Cabin Class-F 4×2 / Semi-Bonnet Class-F 4×2
- 6 : Standard Cabin Class-F 4×4 / Semi-Bonnet Class-F 4×4
- 7 : Double Cabin Class-E 4×2 / Bonnet Class-E 4×2
- 8 : Double Cabin Class-E 4×4 / Bonnet Class-E 4×4
- 9 : Double Cabin Class-F 4×2 / Bonnet Class-F 4×2
- 0 : Double Cabin Class-F 4×4 / Bonnet Class-F 4×4
- A : Super Cabin Class-E 4×2 / Box Class-E 4×2
- B : Super Cabin Class-E 4×4 / Box Class-E 4×4
- C : Super Cabin Class-F 4×2 / Box Class-F 4×2
- D : Super Cabin Class-F 4×4 / Box Class-F 4×4
KND
- 1 : Wagon 4×2 Class-A
- 2 : Wagon 4×2 Class-B
- 3 : Wagon 4×2 Class-C
- 4 : Wagon 4×2 Class-D
- 5 : Wagon 4×2 Class-E
- 6 : Wagon 4×2 Class-F
- 7 : Wagon 4×2 Class-G
- A : Wagon 4×4 Class-A
- B : Wagon 4×4 Class-B
- C : Wagon 4×4 Class-C
- D : Wagon 4×4 Class-D
- E : Wagon 4×4 Class-E
- F : Wagon 4×4 Class-F
- G : Wagon 4×4 Class-G
KNH
- 1 : Box
- 2 : Bonnet
- 3 : Semi-Bonnet
5. Restraint system, Brake system
KNA, KND
Except U.S.A, Canada, Mexico
- 0 : Both side - None
- 1 : Both side - Active belt
- 2 : Both side - Passive belt
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For U.S.A, Canada, Mexico
Code
Seat belt
A
Front air bag
Knee air bag
Side air bag
Curtain air bag
Driver's
Passenger's
Driver's
Passenger's
1st row
2nd row
3rd row
1st row
2nd row
○
○
○
×
×
○
×
×
○
○
3rd row
×
B
○
○
○
×
×
×
×
×
×
×
×
C
○
○
○
×
×
○
×
×
○
○
○
D
○
○
○
×
×
○
○
×
○
○
×
E
○
○
×
×
×
×
×
×
×
×
×
F
○
○
○
×
×
○
×
×
×
×
×
J
○
○
○
○
×
○
○
×
○
○
×
L
○
○
○
○
×
○
×
×
○
○
×
N
○
×
×
×
×
×
×
×
×
×
×
H
○
○
○
○
×
○
×
×
○
○
○
KNC, KNH
Except U.S.A, Canada, Mexico
- 7 : Hydraulic brake system
- 8 : Pneumatic brake system
- 9 : Mixed brake system
For U.S.A, Canada, Mexico
- X : Hydraulic brake system
- Y : Pneumatic brake system
- Z : Mixed brake system
6. Motor type
- E : Battery [LiPB 350 V, 75 Ah] + Motor [3-phase AC 80 KW]
7. Check digit or Driver’s side & Transmission
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen
- A : LHD & MT
- B : LHD & AT
- C : LHD & MT+Transfer
- D : LHD & AT+Transfer
- E : LHD & CVT
- F : LHD & Decelerator
- G : LHD & DCT
- L : RHD & MT
- M : RHD & AT
- N : RHD & MT+Transfer
- S : RHD & AT+Transfer
- T : RHD & CVT
- U : RHD & Decelerator
- V : RHD & DCT
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen
- Check digit : 0 ~ 9, ×
8. Model year
- E : 2014, F : 2015, G : 2016, H : 2017 …
9. Production Plant
- 5 : Hwaseong (Korea)
- 6 : Soha-ri (Korea)
- 7 : Gwangju (Korea)
- T : Seosan (Korea)
10. Vehicle production sequence number
- 000001 ~ 999999
Motor Number
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1. Motor model
2. Motor type
- 80 : 80 KW
3. Production year
- E : 2014, F : 2015, G : 2016, H : 2017...
4. Motor production sequence number
- 000001 ~ 999999
Paint Code
Code
Color
ACN
Snow White Pearl
AAT
Caribbean Blue
ABR
Cherry Black
IM
Titanium Silver
1D
Clear White
General Information
Lift And Support Points
When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place additional weight
in the luggage area before hoisting. When substantial weight is removed from the rear of the vehicle, the center of gravity may change
and can cause the vehicle to tip forward on the hoist.
• Since each tire/wheel assembly weights approximately 14kg (30lbs), placing the front wheels in the luggage area can assist with the
weight distribution.
• Use the same support points to support the vehicle on safety stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.
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General Information
Important Safety Notice
Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety of the
operator. The service procedures and descriptions in this shop manual provide general directions for a service and repair.
Procedure, techniques, tools, and parts for service including the skill of the technician vary. It is impossible to provide advice or caution as to
each case in this manual.
Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle
manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be jeopardized by the
replacement part, service procedure, or tool they chose to use.
Reminds you to be especially careful in those areas where carelessness will cause death or serious injury.
Reminds you to be especially careful in those areas where carelessness may cause death or serious injury.
Reminds you to be especially careful in those areas where carelessness may cause personal injury.
Gives you information that will prevent you from making errors that could damage the vehicle.
Gives you added information that will help you complete a particular procedure.
The following list contains some general WARNINGS that you should follow while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires you to be under the vehicle.
• Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
• Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in park unless instructed otherwise for a
specific operation.
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• Place support against the front and rear surfaces of the tires to help prevent the vehicle from moving.
• Do not smoke while working on a vehicle.
• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle.
• When it is necessary to work under the hood, keep hands and other objects clear of the electric fanblades! Care should betaken be
taken to ensure that the electric fan motor is completely disconnected when working under the hood.
General Information
Towing
If the vehicle needs to be towed, call a professional towing service. Never tow vehicle just on rope or a chain as It is very dangerous.
[Front]
[Rear]
Emergency Towing
There are three popular methods of towing a vehicle :
- The operator loads the vehicle on the back of a truck. This is the best way of transporting the a vehicle.
- The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The other two wheels remain
on the ground.
- The tow truck uses metal cables with hooks on the ends. These hooks wrap around parts of the frame or suspension, and the cables lift
that end of the vehicle off the ground. Attempting this method of towing can seriously damage the vehicle's suspension and body.
If the vehicle cannot be transported by a flat-bed truck, it should be towed by lifting the wheels of the driving axle off the ground. In this case,
the following procedure should be taken :
Reduction Gear Assembly
• Start the motor.
• Shift to [D] position, then [N] position.
• Turn off the motor.
• Improper towing preparation will damage the reduction gear assembly. Precisely the above procedure exactly. If you cannot shift
the reduction gear or start the motor, your vehicle must be transported on a flatbed.
• It is the best partice to tow the vehicle no farther than 30km (19miles), at a speed below 50km/h (30mph).
• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's
weight.
General Information
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Warning And Caution Labels
1. Reservoir cap caution
2. Cooling fan caution
Auxiliary battery Caution Label
3. Auxiliary 12V auxiliary battery caution
4. High voltage caution
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Warning / Caution Label (Cont'd)
A.
Keep lighted cigarettes and all other flames or sparks away from the auxiliary battery.
B.
Wear eye protection when charging or working near a battery. Always provide ventilation when working in an enclosed space.
• When lifting a plastic-cased auxiliary battery, excessive pressure may result in personal injury as acid may leak. Lift with a battery carrier
or with hands by holding opposite corners.
• Never attempt to change the auxiliary battery when the auxiliary battery cables are connected.
• The electrical ignition system works on high voltage.
Never touch these components with the engine running or the ignition switched on.
C.
Keep batteries out of the reach of children as batteries contain highly corrosive SULFURIC ACID. Do not allow auxiliary battery acid to
contact your skin, eyes, clothing or paint finish.
D.
If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate medical attention. If
possible, continue to apply water with a sponge or cloth until medical attention is received.
If electrolyte gets on your skin, thoroughly wash the contacted area. If you feel a pain or a burning sensation, get medical attention
immediately.
E.
Always read the following instructions carefully when handling a auxiliary battery.
F.
Hydrogen, a highly combustible gas, is always present in battery cells and may explode if ignited.
G.
An improperly disposed auxiliary battery can be harmful to the environment and human health.
Always follow(check) local regulations for auxiliary battery disposal.
Handling And Storing The Battery
Auxiliary battery Itself
• Auxiliary batteries should be stored in cool, dry (27 degrees Celsius) places and out of direct
sunlight.
• MF batteries are tightly sealed to prevent acid leakage.
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However, tilting the auxiliary battery to an angle of 45 degrees can cause acid to leak through
the vents on the sides. Therefore, auxiliary batteries should always be stored in their upright
positions. Prevent placing any aqueous or solid (i.e. conductors) bodies on top of the auxiliary
battery.
• It is extremely dangerous to use tools, such as hammers, on the auxiliary battery terminals
when connecting cables to the mounted auxiliary battery.
Auxiliary battery on Vehicle
• When storing the vehicle for a long period of time, make sure to remove the memory fuse in
the junction box to prevent natural discharging.
• Also, if the memory fuse hasn't been removed at the time of storing the vehicle, run the motor
within a month to chare the auxilary battery.
If the memory fuse has been removed at the time of storing the vehicle, run the motor within 3
months to charge the auxiliary battery.
After reconnecting or recharging a discharged auxiliary battery, the ESC OFF indicator may illuminate.
In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position.
Then, restart the motor after the ignition is OFF.
The ESC OFF indicator may turn OFF.
If the ESC OFF indicator does not turn OFF, have the system checked according to DTC.
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Maintenance
Inspection
Battery Voltage and Status
Check the battery voltage and status using the battery tester.
Battery Terminal
1. Move back and forth to check that the battery terminals (A) are loose or corroded.
If the terminals are corroded, clean them.
If battery positive connection is loose, disconnect ground(GND) cable first before attempting to remove or tighten plus
connection, to prevent personal injury.
2. If the battery clamp on battery positive (+) terminal is not seated securely:
(1) Turn ignition switch OFF and disconnect the battery negative (-) terminal.
(2) Tighten battery clamp (A) on battery positive (+) terminal
Battery positive (+) terminal:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
3. If the battery clamp on battery negative (-) terminal is not seated securely:
(1) Tighten battery clamp (A) on battery negative (-) terminal.
Battery negative (-) terminal:
4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
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Battery Condition
Check the battery for damage or deformation. If severe damage, deformation or leakage is found, replace the battery.
Maintenance
Inspection
Radiator hoses
1. Check radiator hoses for the following
(1) Improper attachment
(2) Leaks
(3) Cracks
(4) Damage
(5) Loose connections
(6) Chafing
(7) Deterioration
Coolant level
1. Check the coolant level in the coolant reservoir. Make sure it is between the "F" mark and "L" mark.
2. If the coolant level in the coolant reservoir is at or below the "L" mark, add coolant to bring it between the "L" and "F" marks, then
inspect the cooling system for leaks.
Coolant quality
1. Remove the radiator cap.
2. Check if there are any excessive deposits of rust or scale around the radiator cap sub-assembly and radiator filler hole. Also, the
coolant should be free of oil.
If it is excessively dirty, clean the coolant passage and replace the coolant.
3. Install the radiator cap.
Coolant Refilling And Bleeding
Never remove the reservoir cap when the high voltage system and electric device radiator are hot. Serious burns may be caused
when hot fluid under high pressure escapes from the reservoir.
When pouring electric device coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint.
If any coolant spills, rinse it off immediately.
1. Make sure the electric device system and electric device radiator are cool to the touch.
2. Remove reservoir cap (A).
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3. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
4. Loosen the drain plug (A) and drain the coolant.
5. Tighten the radiator drain plug securely.
6. After draining engine coolant in the reservoir tank, clean the tank.
7. Fill the reservoir with water through the reservoir cap and tighten the cap.
To most effectively bleed the air, pour the water slowly and press on the upper/lower radiator hoses.
8. Connect a GDS and then operate the Electric Water Pump (EWP).
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9. Repeat steps 1 to 8 until the drained water runs clear.
10. Fill fluid mixture of coolant and water (50%) slowly through the reservoir cap. Push the coolant hoses of the radiator so as to bleed
air easily.
• Use only genuine antifreeze/coolant.
• For best corrosion protection, the coolant concentration must be maintained year-round at 55% minimum. Coolant
concentrations less than 55% may not provide sufficient protection against corrosion or freezing.
• For best corrosion protection, the coolant concentration must be maintained year-round at 55% minimum. Coolant
concentrations less than 55% may not provide • sufficient protection against corrosion or freezing.
• Do not mix different brands of antifreeze/coolants.
• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
11. Connect a GDS and then operate the Electric Water Pump (EWP).
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12. When the Electric Water Pump (EWP) operates and electric device coolant circulates, refill electric device coolant through the
coolant filling bottle.
13. Bleeding of the electric device cooling system is completed when the operational sound volume of the Electric Water Pump (EWP)
gets lower and when no air bubbles can be seen in the coolant filling bottle.
After air bleeding is completed, make sure that electric device coolant in the coolant filling bottle flows without air bubbles
during the EWP actuation. If the electric device coolant does not flow or if air bubbles are still visible, repeat steps 10 to 13.
14. After air bleeding is completed, stop the Electric Water Pump (EWP), add electric device coolant to the “F” level on the electric
device reservoir and install the electric device reservoir cap and the electric device reservoir cap.
It takes time to bleed out all the air in the cooling system. Refill coolant when coolant gets cool completely, and then recheck
the coolant level in the reservoir tank 2 - 3 days after replacing coolant.
Coolant capacity
Without Heat Pump : Approx. 4.1 ~ 4.2 L (1.08 ~ 1.11 U.S.gal., 4.33 ~ 4.44 U,S,qt., 3.61 ~ 3.70 lmp.qt)
With Heat Pump : Approx. 4.6 ~ 4.7 L (1.22 ~ 1.24 U.S.gal., 4.86 ~ 4.97 U,S,qt., 4.05 ~ 4.14 lmp.qt)
Maintenance
Inspection
1. Lift the vehicle.
2. Remove the under cover.
(Refer to Traction Motor System - "under cover")
3. Remove the oil filler plug (A).
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4. Check the oil condition and then oil level (A).
If the oil level is low, supplement the oil up to filler plug hole.
5. Install the oil filler plug (A).
Must replace with new gasket when installing the drain plug.
Replacement
Gear differential unit system does not need to be replaced for Normal Usage. If the vehicle is used for any of the Severe Usage
conditions listed below, replace the 120,000 miles. Severe usage is defined as
• Driving in rough road (Bumpy, Gravel, Snowy, Unpaved road, etc)
• Driving in mountain road, ascent/descent
• Repetition of short distance driving
• More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F) .
• Police, Taxi, Commercial type operation or trailer towing, etc
1. Using the lift raise the car.
2. Remove the under cover.
(Refer to Traction Motor System - "under cover")
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3. Remove the drain plug (A) and drain the oil totally and then reinstall the drain plug.
Must replace with new gasket when installing the drain plug.
4. Remove the oil filler plug (A).
5. Supplement up to oil filler plug hole.
6. Install the oil filler plug (A).
7. Install the under cover.
(Refer to Traction Motor System - "under cover")
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Maintenance
Inspection
1. Check the brake fluid level.
Take care as brake fluid can harm your hands and eyes and damage painted surfaces. If fluid gets on your hands or in your
eyes, flush the affected area with clean water immediately.
If brake fluid level is lower than the MIN line, check the clutch line or brake line for leaks and inspect the disc brake pads. If
necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement. Use the specified fluid. Avoid mixing
different brands of fluid.
Specified fluid:SAE J1703 (DOT 3 or DOT 4)
Maintenance
Inspection
Visually check for proper installation, chafing, cracks, deterioration and any leakage
Replace any deteriorated or damaged parts immediately.
Maintenance
Inspection
Check that the brake pedal operates smoothly.
Brake Pedal Height and Stop Lamp Switch clearance Adjustment
1. Disconnect the stop lamp switch connector (A).
2. Adjust the brake pedal height (A) as illustration below.
Pedal height (A):174.2 mm (6.86 in)
Full stroke (C):108 mm (4.25 in)
3. Adjust the stop lamp switch clearance (B).
Stop lamp clearance (B):
1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
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4. Connect the stop lamp switch connector
Maintenance
Inspection
Check the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage.
Front Brake
Front Brake Disc Thickness Check
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm)
from the brake disc outer circle.
Front brake disc thickness
Standard : 23 mm (0.906 in)
Service Limit : 21 mm (0.827 in)
Deviation: Less than 0.005 mm (0.0002 in)
4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Front Brake Pad Check
1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value: 10.5 mm (0.413 in)
Service limit: 2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Front Brake Disc Runout Check
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
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Limit: 0.04 mm (0.0016 in.) or less (new one)
2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake
disc again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Rear Brake
Rear brake disc thickness check
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm)
from the brake disc outer circle.
Brake disc thickness
Standard: 10 mm (0.393 in)
Service limit: 8.4 mm (0.331 in)
Deviation: Less than 0.005mm (0.0002in)
4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Rear Brake Pad Check
1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value: 10 mm (0.394 in)
Service limit: 2.0 mm (0.0787 in)
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2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Rear Brake Disc Runout Check
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit: 0.05 mm (0.0020 in.) or less (new one)
2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake
disc again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Replacement
Front brake pads
1. Remove the front wheel & tire.
2. Loosen the guide rod bolt (B) and pivot the caliper body (A) up out of the way.
3. Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).
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4. Compress the piston into the caliper body using the SST (09581-11000).
5. Place the caliper body (A) on the caliper carrier and tighten the guide rod bolt (B).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
6. Install the front wheel & tire.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Rear Brake Pads
1. Remove the front wheel & tire.
2. Loosen the guide rod bolt (B) and the remove the rear caliper body (A).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
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3. Replace pad retainers (C) and brake pads (B) in the caliper carrier (A).
4. Rotate the caliper piston and push the direction of the arrow.
5. Place the caliper body (A) on the caliper carrier and tighten the guide rod bolt (B).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
Assemble the caliper body so that the piston groove (A) is in-line with the pad center lobe (B).
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* Make sure that the piston and pad are tightly attached.
6. Install the front wheel & tire.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Maintenance
Inspection
1. Check the drive shaft boots for loose clamps, cracks, grease leaks, kinks or damage.
Maintenance
Inspection
1. Check the steering wheel free road.
(1) Turn the steering wheel so that the front wheels are facing straight ahead.
(2) Measure the distance where the steering wheel can be turned without moving the front wheels.
Standard value:30mm (1.18in.) or less
(3) If the play exceeds standard value, inspect the steering column, shaft, and linkages.
2. Check the steering linkage for looseness or damage.
(1) Check that the dust parking and cap are not damaged.
(2) Check that the Bellows bands are not loose.
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(3) Check that the steering gear box is not damaged.
(4) Check that the column and shaft are properly connected to the steering gear box.
Maintenance
Inspection
1. Check the suspension ball joint.
Check the grease leaks, kinks or damage in the front lower arm ball joint.
2. Check the grease leaks, kinks or damage in the tie rod end ball joint.
Maintenance
Inspection
1. Check the tire pressure.
(230+7 kPa (33psi+1.0psi)
2. Check the tire tread wear.
(Refer to Suspension System - "Tire")
3. Check if the wear of tire tread is uneven.
(Refer to Suspension System - "Alignment")
Maintenance
Description
The climate control air filter is located in the blower unit. It eliminates foreign materials and odor. The particle filter performs a role as an
odor filter as well as a conventional dust filter to ensure comfortable interior environment.
Maintenance
Replacement
1. Open the glove box (A).
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2. Remove the air filter panel (A).
3. Remove the filter cover (A) by pressing the knob.
4. Replace the air filter (A) with a new one according to the direction of air filter.
• To remove the filter easily, press the right side inward then pull out the filter.
• In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as possible.
5. Install in the reverse order of removal.
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Driveshaft and axle
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Driveshaft and axle
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Driveshaft and axle
Specification
Joint type
Motor
80KW
Max. permissible angle
Outer
Inner
Outer
Inner
BJ#92
TJ#92
45°
21°
Tightening Torques
Item
Front
Tire wheel hub nuts
N.m
kgf.m
Ib.ft
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Drive shaft coking nut
274.6 ~ 294.2
28.0 ~ 30.0
202.5 ~ 217.0
Strut assembly to knuckle
137.3 ~ 156.9
14.0 ~ 16.0
101.3 ~ 115.7
Caliper guide rod bolt
21.6 ~ 31.4
2.2 ~ 3.2
15.9 ~ 23.1
Brake caliper mounting bolt
78.4 ~ 98.0
8.0 ~ 10.0
57.8 ~ 72.3
Wheel speed sensor mounting bolt
6.8 ~ 10.7
0.7 ~ 1.1
5.0 ~ 7.9
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Brake disc mounting screw
Lower arm to knuckle
Rear
4.9 ~ 5.8
0.5 ~ 0.6
3.6 ~ 4.3
58.8 ~ 70.6
6.0 ~ 7.2
43.4 ~ 52.1
Tie rod end ball joint nut
23.5 ~ 33.3
2.4 ~ 3.4
17.4 ~ 24.5
Tire wheel hub nuts
88.2 ~ 107.8
9.0 ~ 11.0
65.0 ~ 79.5
Rear caliper guide rod bolt
21.6 ~ 31.4
2.2 ~ 3.2
15.9 ~ 23.1
Rear caliper to torsion beam axle
63.7 ~ 73.5
6.5 ~ 7.5
47.0 ~ 54.2
Rear hub assembly to torsion beam axle
49.0 ~ 58.8
5.0 ~ 6.0
36.2 ~ 43.3
4.9 ~ 5.9
0.5 ~ 0.6
3.6 ~ 4.3
Disc fixing screw
Lubricants
Motor
80KW
Joint
Lubricants
Quantity
BJ
GRB006
105g (+10g/0)
TJ
SH06-VX21
140g (+10g/0)
Driveshaft and axle
Special Service Tools
Tool Name / Number
Illustration
Description
Band installer
09495-3K000
Used to install ear type boot band
Puller
09495-33000
Used to remove spider assembly
Ball joint puller
09568-34000
Used to separate ball joint from the front axle.
Driveshaft and axle
Troubleshooting
Trouble Symptom
Probable cause
Scoring of driveshaft ball joint
Vehicle pulls to one side
Vibration
Shimmy
Excessive noise
Remedy
Replace
Wear, rattle or scoring of wheel bearing
Replace
Defective front suspension and steering
Adjustment or Replace
Wear, damage or bending of driveshaft
Replace
Drive Shaft rattle and hub uneveness
Replace
Wear, rattle or scratching of wheel bearing
Replace
Defective wheel balance
Adjustment or Replace
Defective front suspension and steering
Adjustment or Replace
Wear, damage or bending of driveshaft
Replace
Rattle of driveshaft and worn hub splines
Replace
Wear, rattle or scoring of wheel bearing
Replace
Loose hub nut
Adjustment or Replace
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Defective front suspension and steering
Driveshaft and axle
Component (1)
1. Driveshaft (RH)
2. Circlip
Component (2)
[LH]
3. Driveshaft (LH)
Adjustment or Replace
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1. BJ assembly
2. BJ circlip
3. BJ boot band
4. BJ boot
[RH]
5. Shaft
6. TJ boot band
7. TJ boot
8. Spider assembly
9. Snap ring
10. TJ housing
11. TJ circlip
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1. BJ assembly
2. BJ circlip
3. BJ boot band
4. BJ boot
5. Shaft
6. TJ boot band
7. TJ boot
8. Spider assembly
Driveshaft and axle
Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
9. Snap ring
10. TJ housing
11. TJ circlip
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Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3. Remove the driveshaft coking nut (A).
Tightening torque:
274.6 ~ 294.2 N.m (28.0 ~ 30.0 kgf.m, 202.5 ~ 217.0 lb-ft)
• The driveshaft lock nut should be replaced with new ones.
• After installation driveshaft lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.
4. Remove the tie rod end ball joint (C) from the knuckle by using the SST (09568-34000).
(1) Remove the split pin (A).
(2) Remove the castle nut (B).
(3) Use the SST (09568-34000).
Tightening torque:
23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 19.4 ~ 24.6lb-ft)
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• When using SST, be sure not to damage the dust cover of lower arm ball joint.
• Keep SST tied to the car because there is arisk of injury by dropping the SST duringremoval of the lower arm ball joint.
• The peripheral parts may be damaged when removing the lower arm ball joint with a general tool such as lever, so be sure to
use SST.
5. Remove the lower arm (A) from the knuckle.
Tightening torque:
58.8 ~ 70.6 N.m (6.0 ~ 7.2 kgf.m, 43.4 ~ 52.1 lb-ft)
6. Using a plastic hammer, disconnect driveshaft (A) from the axle hub (B).
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7. Insert a pry bar (A) between the transaxle case and joint case, and separate the drive shaft (B) from the transaxle case.
8. Install in the reverse order of removal.
9. Check the front alignment.
(Refer to Suspension System - "Front Alignment")
Inspection
1.
2.
3.
4.
Check the driveshaft boots for damage and deterioration.
Check the ball joint for wear and damage.
Check the splines for wear and damage.
Check the dynamic damper for cracks, wear and position.
5. Check the driveshaft for cracks and abnormal wear.
Disassembly
• Do not disassemble BJ assembly
• Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
• The boot band should be replaced with a new one.
1. Remove the Front Driveshaft.
(Refer to Driveshaft Assembly - "Front Driveshaft")
2. Remove the BJ circlip (B) from the TJ housing (A).
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3. Remove both boot bands from the TJ housing.
4. Pull out the boot from the transaxle side joint (TJ).
5. While separating joint boot (A) of the transaxle side,wipe the grease in VTJ case (B) and lay them in the correct order.
• Make alignment marks (D) on spider roller assembly (A), TJ housing (B), and shaft spline (C) to aid reassembly.
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6. Remove the snap ring (A) from the shaft.
7. Remove the spider assembly (B) from the driveshaft (A) using the special tool (09495-33000).
8. Clean the spider assembly.
9. Remove the TJ boot (A).
• For reusing the boot (A), wrap tape (B) around the driveshaft splines (C) to protect the boot (A).
Reassembly
1. Wrap tape around the driveshaft spline(TJ) to prevent damage to the boot.
2.
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Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring (B) on the driveshaft
splines (C).
3. Add grease to the joint boot.
4. Install both boot bands.
5. To control the air in the TJ boot, keep the specified distance between the boot bands when they are tightened.
Motor
80KW
6. Using the SST(09495-3K000), secure the TJ boot bands.
Clearance (A):2.0 mm (0.0787 in.) or less
Distance (L) mm (in.)
LH side
RH side
546.3
804.7
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7. Install the Front Driveshaft.
(Refer to Driveshaft Assembly - "Front Driveshaft")
8. Check the front alignment.
(Refer to Suspension System - "Front Alignment")
Driveshaft and axle
Components
1. Brake disc
2. Wheel hub assembly
3. Hub bolt
4. Dust cover
Driveshaft and axle
5. Knuckle
6. Hub bearing
7. Snap ring
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Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3. Loosen the guide rod bolt (B) and pivot the caliper (A) up out of the way.
Tightening torque:
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
4. Remove the brake pads (A).
5. Remove the brake caliper mounting bolts (A), and then place the brake caliper assembly (B) with wire.
Tightening torque:
78.4 ~ 98.0 N.m (8.0 ~ 10.0 kgf.m, 57.8 ~ 72.3 lb-ft)
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6. Loosen the front brake disc mount screw (B) and then remove the front brake disc (A).
Tightening torque:
4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
7. Remove driveshaft nut (A) from the front hub.
Tightening torque:
274.6 ~ 294.2 N.m (28.0 ~ 30.0 Kgf.m, 202.5 ~ 217.0 lb-ft)
• The driveshaft lock nut should be replaced with new ones.
• After installation driveshaft lock nut, stake the lock nut using a chisel and hammer as shown in the illustration below.
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8. Remove the tie rod end ball joint (C) from the knuckle by using the SST (09568-34000).
(1) Remove the split pin (A).
(2) Remove the castle nut (B).
(3) Use the SST (09568-34000).
Tightening torque:
23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 19.4 ~ 24.6lb-ft)
• When using SST, be sure not to damage the dust cover of lower arm ball joint.
• Keep SST tied to the car because there is arisk of injury by dropping the SST duringremoval of the lower arm ball joint.
• The peripheral parts may be damaged when removing the lower arm ball joint with a general tool such as lever, so be sure to
use SST.
9. Loosen the mount bolt and then remove the wheel speed sensor (A) from knuckle.
Tightening torque:
6.8 ~ 10.7 N.m (0.7 ~ 1.1 kgf.m, 5.0 ~ 7.9 lb-ft)
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10. Loosen the bolt & nut and then remove the lower arm (A).
Tightening torque:
58.8 ~ 70.6 N.m (6.0 ~ 7.2 kgf.m, 43.4 ~ 52.1 lb-ft)
11. Disconnect the driveshaft (A) from the front hub assembly.
12. Loosen the strut mounting bolts (A) and then remove the knuckle assembly (B).
Tightening torque:
137.3 ~ 156.9 N.m (14.0 ~ 16.0 kgf.m, 101.3 ~ 115.7 lb-ft)
Inspection
1. Check the hub for cracks and the splines for wear.
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2. Check the brake disc for scoring and damage.
3. Check the knuckle for cracks.
4. Check the bearing for cracks or damage.
Installation
1. Install in the reverse order of removal.
Use a SST (09581-11000) when installing the brake caliper assembly.
(Refer to Brake System - "Front Disc Brake")
2. Check the front alignment.
(Refer to Suspension System - "Front Alignment")
Driveshaft and axle
Components
1. Rear dust cover
2. Rear wheel hub assembly
Driveshaft and axle
Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the rear wheel and tire (A) from rear hub.
3. Rear brake disc
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Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
3. Loosen the guide rod bolt (B) and the remove the rear caliper body (A).
Tightening torque:
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
4. Remove the pads (B), in the caliper carrier (A).
5. Remove the brake caliper mounting bolts (B), and then place the brake caliper assembly (A) with wire.
Tightening torque:
63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)
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6. Disconnect the wheel speed sensor connector (A).
7. Loosen the screws (B), and then remove the brake disc (A).
Tightening torque:
4.9 ~ 5.8 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
8. Loosen the bolts and then remove the hub bearing (A).
Tightening torque:
49.0 ~ 58.8 N.m (5.0 ~ 6.0 kgf.m, 36.2 ~ 43.3 lb-ft)
9. Remove the hub bearing by using the rubber hammer.
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10. Install in the reverse order of removal.
Inspection
1.
2.
3.
4.
Check the hub for cracks and the splines for wear.
Check the brake disc for scoring and damage.
Check the rear axle carrier for cracks.
Check the bearing for cracks or damage.
Installation
1. Install in the reverse order of removal
Use a SST (09581-11000) when installing the brake caliper assembly.
(Refer to Brake System - "Front Disc Brake")
2. Check the front alignment.
(Refer to Suspension System - "Front Alignment")
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Suspension System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Page 3 sur 115
Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Suspension System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Suspension System
Specifications
Front Suspension
Item
Specification
Suspension type
MacPherson Strut
Shock absorber Type
Coil spring
Free Height [I.D. color]
Gas
327.9mm (12.9842 in.) [Violet - Yellow]
Rear Suspension
Item
Suspension type
Shock absorber Type
Coil spring
Specification
Torsion Beam Axle
Gas (Mono tube)
Free Height [I.D. color]
318.0 mm (12.5297 in.) [White - Gray]
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Wheel & Tire
Item
Wheel
Specification
Aluminum
6.5J * 16
Tire
205/60 R16
Tire pressure
230+7 kPa (33psi+1.0psi)
Wheel Alignment
Specification
Item
Individual
Toe-in
Total
Front
Rear
0.05°±0.1°
0.15° (+0.25° / -0.15°)
0.1°±0.2°
0.3° (+0.5° / -0.3°)
Camber angle
-0.5°±0.5°
Caster angle
5.1°±0.5°
-1.5°±0.5°
-
King-pin angle
13.4°±0.5°
Ride height
395±10mm
Tightening Torques
Front Suspension
Item
Tightening torque (kgf.m)
Nm
kgf.m
lb-ft
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Wheel speed sensor mounting bolt
6.8 ~ 10.7
0.7 ~ 1.1
5.0 ~ 7.9
wheel speed sensor wiring bracket bolt
8.8 ~ 13.7
0.9 ~ 1.4
6.5 ~ 10.1
Wheel Hub nuts
Strut assembly upper mounting nut
44.1 ~ 58.8
4.5 ~ 6.0
32.5 ~ 43.3
Strut assembly lower mounting bolt
137.3 ~ 156.9
14.0 ~ 16.0
101.3 ~ 115.7
Strut assembly lock nut
58.8 ~ 68.6
6.0 ~ 7.0
43.4 ~ 50.6
Lower arm mounting bolt (forward)
117.7 ~ 137.3
12.0 ~ 14.0
86.8 ~ 101.3
Lower arm mounting bolt (rearward)
115.7 ~ 130.2
156.9 ~ 176.5
16.0 ~ 18.0
Lower arm ball joint mounting bolt & nut
58.8 ~ 70.6
6.0 ~ 7.2
43.4 ~ 52.1
Stabilizer link nut (to strut)
98.1 ~ 117.7
10.0 ~12.0
72.3 ~ 86.8
Stabilizer bar nut ( to stabilizer link)
98.1 ~ 117.7
10.0 ~ 12.0
72.3 ~ 86.8
Stabilizer bracket mounting bolts
44.1 ~ 53.9
4.5 ~ 5.5
32.5 ~ 39.8
Tie rod end nut
24.5 ~ 33.3
2.4 ~ 3.4
17.4 ~ 24.5
Universal joint mounting bolt
Roll rod stopper & bracket bolt
Roll rod stopper mounting bolt
Cross member mounting (to body)
32.4 ~ 37.3
3.3 ~ 3.8
23.9 ~ 27.5
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
156.9 ~ 176.5
16.0 ~ 18.0
115.7 ~ 130.2
Power electric frame support mounting nut [LH]
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Power electric frame support mounting nut [RH]
78.5 ~ 98.1
8.0 ~ 10.0
57.9 ~ 72.3
Accumulator mounting bolt
6.8 ~ 10.7
0.7 ~ 1.1
5.0 ~ 7.9
Rear Suspension
Item
Wheel Hub nuts
Tightening torque (kgf.m)
Nm
kgf.m
lb-ft
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Rear caliper guide rod bolt
21.6 ~ 31.4
2.2 ~ 3.2
15.9 ~ 23.1
Rear caliper mounting bolt
63.7 ~ 73.5
6.5 ~ 7.5
47.0 ~ 54.2
Wheel speed sensor mounting bolt
6.8 ~ 10.7
0.7 ~ 1.1
5.0 ~ 7.9
Parking cable bracket
8.8 ~ 13.7
0.9 ~ 1.4
6.5 ~ 10.1
Disc fixing screw
4.9 ~ 5.9
0.5 ~ 0.6
3.6 ~ 4.3
Shock absorber upper bolt
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Shock absorber lower bolt
98.1 ~ 117.7
10.0 ~ 12.0
72.3 ~ 86.8
Rear heb assembly
49.0 ~ 58.8
5.0 ~ 6.0
36.1 ~ 43.3
Torsion beam axle to body
98.1 ~ 117.7
10.0 ~ 12.0
72.3 ~ 86.8
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Suspension System
Special Service Tools
Tool Name / Number
Illustration
Description
Strut spring compressor
09546-26000
Compression of coil spring
Ball joint puller
09568-34000
Remove the ball joint from front axle
Suspension System
Troubleshooting
Vehicle inspection
SYMPTOM CHART
Symptom
Suspect Area
Front stabilizer bar
Remedy (See page)
Under these conditions, the noise is
acceptable.
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Squeak or grunt-noise from the front
suspension, occurs more in cold ambient
temperatures-more noticeable over rough
roads or when turning
Clunk-noise from the front suspension, occurs Loose front struts or shocks
in and out of turns
Inspect for loose nuts or bolts.
Tighten to specifications.
Clunk-noise from the rear suspension, occurs Loose rear suspension components
when shifting from reverse to drive
Inspect for loose or damaged rear suspension
components.
Repair or install new components as
necessary.
Click or pop - noise from the front suspension, Worn or damaged ball joints
more noticeable over rough roads or over
bumps
Install new lower arm as necessary.
Click or pop - noise occurs when vehicle is
turning
Worn or damaged ball joints
Install new lower arm as necessary.
Damaged or worn Birfield joint
Repair or install a new Birfied joint as
necessary.
See DS group - driveshaft.
Click or snap - occurs when accelerating
around a corner
Go to detailed test A.
Front suspension noise - A squeak, creak, or Steering components
rattle noise - occurs mostly over bumps or
Loose or bent front struts or shock absorbers
rough roads
Damaged spring or spring mounts
Damaged or worn arm bushings
Worn or damaged stabilizer bar bushing or
links
Uneven seating surface between the insulator Repair or install a new parts as necessary.
Groaning or grinding - noise from the front
and panel by the burrs around the strut
strut, occurs when driving on bumpy roads or
insulator mounting bolts and the insulator
turning the vehicle
boltes mounting holes
Rear suspension noise - a squeak, creak or
rattle noise - occurs mostly over bumps or
rough roads
Loose or bent rear shock absorbers
Damaged spring or spring mounts
Damaged or worn control arm bushings
Go to detailed test B.
Shudder - occurs during acceleration from a
slow speed or stop
Rear axle assembly mis-positioned
Damaged or worn front suspension
components
Check the axle mounts and rear suspension
for damage or wear. Repair as necessary.
Check for a loose stabilizer bar, damaged or
loose strut/strut bushings or loose or worn ball
joints. Inspect the steering linkage for wear or
damage. Repair or Install new components as
necessary.
Shimmy - most noticeable on
coast/deceleration - also hard steering
condition
Excessive positive caster
Check the caster alignment angle.
Correct as necessary.
Tire noise - hum/moan at constant speeds
Abnormal wear patterns
Spin the tire and Check for tire wear. Install a
new tire as necessary. Inspect for
damaged/worn suspension components.
Perform wheel alignment.
Tire noise - noise tone lowers as the vehicle
speed is lowered
Out-of-balance tire
Balance the tire and road test. Install a new
tire as necessary.
Nail puncture or stone in tire tread
Inspect the tire. Repair or replace as
necessary.
Tire noise - ticking noise, change with speed
Wheel and tire - vibration and noise concern is Damaged or worn tire
directly related to vehicle speed and is not
affected by acceleration, coasting or
decelerating
Go to detailed test C.
Tire wobble or shudder - occurs at lower
speeds
Damaged wheel bearings
Spin the tire and check for abnormal wheel
bearing play or roughness. Adjust or Install
new wheel bearings as necessary.
See DS group - front/rear axle.
Damaged wheel
Inspect the wheel for damage. Install a new
wheel as necessary.
Damaged or worn suspension components
Inspect the suspension components for wear
or damage. Repair as necessary.
Loosen wheel nuts
Check the wheel nuts.
Tighten to specification.
Damaged or uneven tire wear
Page 13 sur 115
Spin the tire and Check for abnormal tire wear
or damage. Install a new tire as necessary.
Tire shimmy or shake - occurs at lower
speeds
Wheel/tire out of balance
Uneven tire wear
Check for abnormal tire wear. Install a new
tire as necessary.
Excessive radial runout of wheel or tire
Perform a radial runout test of the wheel and
tire.
Install a new tire as necessary.
Worn or damaged wheel studs or elongate
stud holes
Inspect the wheel studs and wheels.
Install new components as necessary.
Excessive lateral runout of the wheel or tire
Perform a lateral runout test of the wheel and
tire.
Check the wheel, tire and hub. Repair or
Install new components as necessary.
Foreign materal between the brake disc and
hub.
Clean the mounting surfaces of the brake disc
and hub.
See DS group - front/rear axle.
High speed shake or shimmy - occurs at high Excessive wheel hub runout
speeds
Damaged or worn tires
Damaged or worn wheel bearings
Worn or damaged suspension or steering
linkage
Brake disc or drum imbalance
Go to detailed test D.
Drift left or right
Tires
Steering linkage
Alignment
Base brake system
Go to detailed test E.
Steering wheel
Alignment
Steering linkage
Front lower arm ball joint
Go to detailed test F.
Tracks incorrectly
Rear suspension
Caster
Go to detailed test G.
Rough ride
Front strut and spring assembly
Rear shock absorber and spring assembly
Go to detailed test H.
Excessive noise
Front or rear stabilizer bar components
Springs
Suspension components
Shock absorbers
Go to detailed test I.
Incorrect tire wear
Tire or unbalanced wheels
Tire inflation
Strut
Alignment
Go to detailed test J.
Vibration
Wheel/tire
Front wheel driveshaft(s)
Steering system
Strut and spring assembly
Spring and strut mounting
Front lower arm ball joint
Front lower arm mounting bolt bushing
Stabilizer bar bushings
Wheel hubs and bearing
Rear suspension arms and bushings
Go to detailed test K.
Vehicle leans
Tire/wheel
Vehicle load
Suspension components
Incorrect ride height
Poor steering returnability
High knuckle rotating torque
Alignment
Inflate tires to specification.
Redistribute the load as necessary.
Visually inspect the suspention system.
Correct the ride height as necessary.
Go to detailed test E.
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DETAILED TEST A : FRONT SUSPENSION NOISE
CONDITIONS
DETAILS/RESULTS/ACTIONS
A1. ROAD TEST THE VEHICLE
1. Test drive the vehicle.
2. During the road test, drive the vehicle over a rough road. Determine from which
area/component the noise is originating.
● Is there a squeak, creak or rattle noise ?
→ YES
Go toA2.
→ NO
The suspension system is OK. Conduct a diagnosis on other suspect systems.
A2. INSPECT THE STEERING SYSTEM
1. Check the steering system for wear or damage.
Perform a steering linkage test.
Inspect the tire wear pattern.
● Are the steering components worn or damaged ?
→ YES
Repair the steering system. Install new components as necessary. Test the system for
normal operation.
→ NO
Go toA3.
A3. FRONT SHOCK ABSORBER/STRUT CHECK
1. Check the front shock absorbers/strut mounts for loose bolts or nuts.
2. Check the front shock absorbers/struts for damage. Perform a shock absorber check.
● Are the front shock absorbers/struts loose or damaged ?
→ YES
Tighten to specifications if loose.
Install new front shock absorbers/struts if damaged. Test the system for normal
operation.
→ NO
Go toA4.
A4. CHECK THE FRONT SPRINGS
Check the front spring and front spring mounts/brackets for wear or damage
● Are the front springs or spring mounts/brackets worn or damaged ?
→ YES
Repair or Install new components as necessary. Test the system for normal operation.
→ NO
Go toA5.
A5. CHECK THE STABILIZER BAR
1. Check the stabilizer bar bushings and links for damage or wear.
2. Check the stabilizer bar for damage.
3. Check for loose or damaged stabilizer brackets.
● Are the stabilizer bar/track bar components loose, worn or damaged ?
→ YES
Repair or Install new components as necessary. Test the system for normal operation.
→ NO
Suspension system is OK. Conduct diagnosis on other suspect systems.
DETAILED TEST B : REAR SUSPENSION NOISE
CONDITIONS
DETAILS/RESULTS/ACTIONS
B1. ROAD TEST THE VEHICLE
1. Test drive the vehicle.
2. During the road test, drive the vehicle over a rough road. Determine from which
area/component the noise is originating.
● Is there a squeak, creak or rattle noise ?
→ YES
Go toB2.
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→ NO
The suspension system is OK. Conduct a diagnosis on other suspect systems.
B2. REAR SHOCK ABSORBER/STRUT CHECK
1. Raise and support the vehicle. See GI group - lift support point.
2. Check the rear shock absorber/strut mounts for loose bolts or nuts.
3. Check the rear shock absorbers/strut for damage. Perform a shock absorber check.
● Are the rear shock absorbers/struts loose or damaged ?
→ YES
Tighten to specifications if loose.
Install new rear shock absorbers/struts if damaged. Test the system for normal
operation.
→ NO
Go toB3.
B3. CHECK THE REAR SPRINGS
Check the rear springs and rear spring mounts/brackets for wear or damage.
● Are the rear springs or spring mounts/brackets worn or damaged ?
→ YES
Repair or Install new components as necessary. Test the system for normal operation.
→ NO
Go toB4.
B4. CHECK THE TRAILING ARMS
1. Inspect the trailing arm bushings for wear or damage. Check for loose trailing arm bolts.
2. Inspect for twisted or bent trailing arms.
● Are the trailing arms loose, damaged or worn ?
→ YES
Repair or Install new components as necessary. Test the system for normal operation.
→ NO
Suspension system is OK. Conduct diagnosis on other suspect systems.
DETAILED TEST C : WHEEL AND TIRE
CONDITIONS
DETAILS/RESULTS/ACTIONS
C1. ROAD TEST THE VEHICLE
Wheel or tire vibrations felt in the steering wheel are most likely related to the front
wheel or tire. Vibration felt through the seat are most likely related to the rear wheel or
tire. This may not always be true, but it can help to isolate the problem to the front or
rear of the vehicle.
Test drive the vehicle at different speed ranges.
During the road test, if the vibration can be eliminated by placing the vehicle in neutral or is
affected by the speed of the engine, the cause is not the wheels or tires.
● Is there a vibration and noise ?
→ YES
Go toC2.
→ NO
The wheel and tires are OK. Conduct a diagnosis on other suspect systems.
C2. CHECK THE FRONT WHEEL BEARINGS
Check the front wheel bearings.
Refer to Wheel Bearing Check (See DS group - front axle).
● Are the wheel bearings OK ?
→ YES
Go toC3.
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→ NO
Inspect the wheel bearings. Adjust or Repair as necessary. Test the system for normal
operation.
C3. INSPECT THE TIRES
1. Check the tires for missing weights.
2. Check the wheels for damage.
3. Inspect the tire wear pattern.
● Do the tires have an abnormal wear pattern ?
→ YES
Correct the condition that caused the abnormal wear. Install new tire(s).
Test the system for normal operation.
→ NO
Go toC4.
C4. TIRE ROTATION DIAGNOSIS
1. Spin the tires slowly and watch for signs of lateral runout.
2. Spin the tires slowly and watch for signs of radial runout.
● Are there signs of visual runout ?
→ YES
Go toC5.
→ NO
Check the wheel and tire balance.
Correct as necessary. Test the system for normal operation.
C5. RADIAL RUNOUT CHECK ON THE TIRE
Measure the radial runout of the wheel and tire assembly. A typical specification for total
radial runout is 1.15mm (0.059 inch).
● Is the radial runout within specifications ?
→ YES
Go toC8.
→ NO
Go toC6.
C6. RADIAL RUNOUT CHECK ON THE WHEEL
Measure the radial runout of the wheel. A typical specification for total radial runout is
1.14mm (0.045 inch.).
● Is the radial runout within specifications ?
→ YES
Install a new tire. Test the system for normal operation.
→ NO
Go toC7.
C7. CHECK THE HUB/BRAKE DISC OR DRUM PILOT RUNOUT OR BOLT CIRCLE RUNOUT
Measure the pilot or bolt circle runout. A typical specification for radial runout is :
● pilot runout - less than 0.15mm (0.006 inch.)
● bolt circle runout - less than 0.38 mm (0.015 inch.)
● Is the radial runout within specification ?
→ YES
Install a new wheel. Test the system for normal operation.
→ NO
Repair or Install new components as necessary.
C8. LATERAL RUNOUT CHECK ON THE TIRE
Measure the lateral runout of the wheel and tire assembly. A typical specification for total
lateral runout is 2.5mm (0.098 inch).
● Is the lateral runout within specifications ?
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→ YES
Wheel and tires are OK. Conduct diagnosis on other suspect systems.
→ NO
Go toC9.
C9. LATERAL RUNOUT CHECK ON THE WHEEL
Measure the lateral runout of the wheel. A typical specification for total radial runout is
1.2mm (0.047 inch.)
● Is the lateral runout within specifications ?
→ YES
Install a new tire. Test the system for normal operation.
→ NO
Go toC10.
C10. CHECK THE FLANGE FACE LATERAL RUNOUT
Measure the flange face lateral runout. A typical specification for lateral runout is :
● hub/brake disc - less than 0.13mm (0.005 inch)
● Is the lateral runout within specifications ?
→ YES
Install a new wheel. Test the system for normal operation.
→ NO
Repair or Install new components as necessary.
DETAILED TEST D :
CONDITIONS
DETAILS/RESULTS/ACTIONS
D1. CHECK FOR FRONT WHEEL BEARING ROUGHNESS
1. Raise and support the front end of the vehicle so that the front wheel and tire
assemblies can spin.
See GI group - lift support point.
2. Spin the front tires by hand.
● Do the wheel bearings feel rough ?
→ YES
Inspect the wheel bearings. Repair as necessary. Test the system for normal operation.
→ NO
Go toD2.
D2. CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS
Check the end play of the front wheel bearings.
● Is the end play OK ?
→ YES
Go toD3.
→ NO
Adjust or Repair as necessary. Test the system for normal operation.
D3. MEASURE THE LATERAL RUNOUT AND THE RADIAL RUNOUT OF THE FRONT WHEELS ON THE VEHICLE
Measure the lateral runout and the radial runout of the front wheels on the vehicle. Go to
detailed test C.
● Are the measurements within specifications ?
→ YES
Go toD4.
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→ NO
Install new wheels as necessary and Balance the assembly. Test the system for normal
operation.
D4. MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE
Measure the lateral runout of the front tires on the vehicle. Go to detailed test C.
● Is the runout within specifications ?
→ YES
Go toD5.
→ NO
Install new tires as necessary and Balance the assembly. Test the system for normal
operation.
D5. MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES ON THE VEHICLE
Measure the radial runout of the front tires on the vehicle. Go to detailed test C.
● Is the runout within specifications ?
→ YES
Balance the front wheel and tire assemblies. If any tire cannot be balanced, Install a new
tire. Test the system for normal operation.
→ NO
Go toD6.
D6. MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY
Mark the high runout location on the tire and also on the wheel. Break the assembly down
and rotate the tire 180 degrees (halfway around) on the wheel. Inflate the tire and measure
the radial runout.
● Is the runout within specifications ?
→ YES
Balance the assembly. Test the system for normal operation.
→ NO
If the high spot is not within 101.6mm (4 inches) of the first high spot on the tire, Go toD7.
D7. MEASURE THE WHEEL FLANGE RUNOUT
Dismount the tire and mount the wheel on a wheel balancer. Measure the runout on both
wheel flanges. Go to detailed test C
● Is the runout within specifications ?
→ YES
Locate and Mark the low spot on the wheel. Install the tire, matching the high spot on the
tire with the low spot on the wheel. Balance the assembly. Test the system for normal
operation. If the condition persists, Go to
D8.
→ NO
Install a new wheel. Check the runout on the new wheel. If the new wheel is within limits,
locate and Mark the low spot. Install the tire, matching the high spot on the tire with the low
spot on the wheel. Balance the assembly. Test the system for normal operation. If the
condition persists, Go to
D8.
D8. CHECK FOR VIBRATION FROM THE FRONT OF THE VEHICLE
Spin the front wheel and tire assemblies with a wheel balancer while the vehicle is raised
on a hoist. Feel for vibration in the front fender or while seated in the vehicle.
● Is the vibration present ?
→ YES
Substitute known good wheel and tire assemblies as necessary.
Test the system for normal operation.
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→ NO
Check the driveline components. Test the system for normal operation.
DETAILED TEST E : DRIFT LEFT OR RIGHT
CONDITIONS
DETAILS/RESULTS/ACTIONS
E1. CHECK THE TIRES
Inspect the tires for excessive wear or damage.
● Are the tires excessively worn or damaged ?
→ YES
Install new tires.
→ NO
Go toE2.
E2. CHECK THE STEERING LINKAGE
1. Raise and support the vehicle.
2. Check the steering components for indications of excessive wear or damage.
See ST group - specification.
● Is there an indication of excessive wear or damage ?
→ YES
Repair or Install new components as necessary.
→ NO
Go toE3.
E3. CHECK THE VEHICLE ALIGNMENT
1. Place the vehicle on an alignment rack.
Check the vehicle alignmnt.
● Is the alignment within specification ?
→ YES
Go toE4.
→ NO
Adjust the alignment as necessary.
E4. BRAKE DRAG DIAGNOSIS
Apply the brakes while driving.
● Does drift or pull occur when the brakes are applied ?
→ YES
See BR group - specification.
→ NO
If the steering wheel is in the center, the vehicle is OK.
If the steering wheel is off-center, Go to Detailed TestF.
DETAILED TEST F : STEERING WHEEL OFF-CENTER
CONDITIONS
DETAILS/RESULTS/ACTIONS
F1. CHECK THE CLEAR VISION
Place the vehicle on an alignment rack.
● Is the clear vision within specification ?
→ YES
Go toF2.
→ NO
Adjust the clear vision to specification.
F2. INSPECT THE STEERING COMPONENTS
1. Raise and support the vehicle.
2. Inspect the steering components for excessive wear or damage.
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See ST group - specification.
● Are the steering components excessively worn or damaged ?
→ YES
Repair or Install new components as necessary.
→ NO
If it tracks corectly, vehicle is OK.
If it tracks incorrectly, Go to Detailed Test
DETAILED TEST G : TRACKS INCORRECTLY
CONDITIONS
DETAILS/RESULTS/ACTIONS
G1. CHECK THE CASTER
Place the vehicle on an alignment rack.
● Is the caster within specification ?
→ YES
Go toG2.
→NO
Replace bent or damaged parts.
G2. CHECK THE REAR SUSPENSION
1. Measure the vehicle wheel base for LH and RH.
2. Compare the measurements.
● Are the measurements the same ?
→ YES
If the ride is smooth, vehicle is OK.
If the ride is rough, Go to Detailed Test
→ NO
Inspect the rear suspension components for wear or damage.
Repair or Install new components as necessary.
DETAILED TEST H : ROUGH RIDE
CONDITIONS
DETAILS/RESULTS/ACTIONS
H1. CHECK THE FRONT SHOCK ABSORBER
1. Raise support the vehicle.
2. Inspect the front shock absorber for oil leaks or damage.
● Are the tires excessively worn or damaged ?
→ YES
Install new front shock absorbers.
→ NO
Go toH2.
H2. CHECK THE REAR SHOCK ABSORBERS
Inspect the rear shock absorbers for oil leaks or damage.
● Are the rear shock absorbers leaking ?
→ YES
Install new rear shock absorbers.
→ NO
The vehicle is OK. Go toTROUBLESHOOTING.
DETAILED TEST I : EXCESSIVE NOISE
CONDITIONS
DETAILS/RESULTS/ACTIONS
I1. INSPECT THE SUSPENSION
1. Raise and support the vehicle.
2. Inspect the shock absorber mounting bolts.
● Are the mounting bolts loose or broken ?
→ YES
Tighten or Install new shock absorber mounting bolts.
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→ NO
Go toI2.
I2. INSPECT THE SPRING AND TORSION BARS
Inspect the springs and stabilizer bars for damage.
● Are the spring or stabilizer bars damaged ?
→ YES
Install new spring and/or stabilizer bars.
→ NO
Go toI3.
I3. INSPECT THE FRONT SUSPENSION
Inspect the front suspension components for excessive wear or damage.
● Are the front suspension components worn or damaged ?
→ YES
Install new front suspension components.
→ NO
The vehicle is OK. Go toTROUBLESHOOTING.
DETAILED TEST J : INCORRECT TIRE WEAR
CONDITIONS
DETAILS/RESULTS/ACTIONS
J1. INSPECT THE TIRES
1. Raise and support the vehicle.
2. Inspect the tires for uneven wear on the inner or outer shoulder.
● Is there uneven tire wear ?
→ YES
Align the vehicle. Install new tires if badly worn.
→ NO
Go toJ2.
J2. UNEVEN TIRE WEAR
Inspect the tires for a feathering pattern.
● Do the tires have a feathering pattern ?
→ YES
Align the vehicle. Install new tires if badly worn.
→ NO
Go toJ3.
J3. CHECK FOR CUPPED TIRE
Inspect the tires for cupping or dishing.
● Are the tires cupped or dished ?
→ YES
Balance and Rotate the tires.
→ NO
The vehicle is OK. Go toTROUBLESHOOTING.
DETAILED TEST K : VIBRATION
CONDITIONS
DETAILS/RESULTS/ACTIONS
K1. ROAD TEST
Accelerate the vehicle to the speed at which the customer indicated the vibration occured.
● Is the vibration present ?
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→ YES
Go toK2.
→ NO
The vehicle is OK. Go toTROUBLESHOOTING.
K2. INSPECT THE TIRES
1. Raise and support the vehicle with a frame contact hoist.
2. Inspect the tires for extreme wear or damage, cupping, or flat spots.
● Are the tires OK ?
→ YES
Go toK3.
→ NO
Check the suspension components for misalignment, abnormal wear, or damage that
may have contributed to the tire wear.
Correct the suspension concerns and Install new tires.
K3. INSPECT THE WHEEL BEARINGS
Spin the tires by hand to check for wheel bearing rougness.
● Is the front wheel bearing OK ?
→ YES
Go toK4.
→ NO
Install new front wheel bearings as necessary.
See Ds group - front axle.
K4. TIRE/WHEEL BALANCE
Check the tire/wheel balance.
● Are the tires balanced ?
→ YES
Go toK5.
→ NO
Balance the tires and wheels as necessary.
K5. MEASURE THE RUNOUTS
For each wheel position measure, locate and mark the following items.
- High point of the tire/wheel assembly total radial runout
- High point of the wheel radial runout
- High point of the wheel lateral runout
● Are the runouts as specified ?
→ YES
Go toTires/Wheels.
→ NO
Go toK6.
K6. SUBSTITUTE THE WHEELS AND TIRE
1. Substitute a known good set of wheels and tires.
2. Perform a road test.
3. If the vehicle still exhibits a shake or vibration, note the vehicle speed and/or engine
rpm which it occurs.
● Is the vibration felt ?
→ YES
Engine/transmission imbalance.
See the specification of TR group, EM group, FL group and EC group.
→ NO
Install the original tire/wheel assemblies one by one, Road testing at each step until the
damaged tire(s)/wheel(s) as necessary. Test the system for normal operation.
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Wheel /tire noise, vibration and harshness concerns are directly related to vehicle speed and are not generally affected by acceleration,
coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine
rpm, or is eliminated by placing the transmission in Neutral is not related to the tire and wheel. As a general rule, tire and wheel vibrations
felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and
wheel assemblies. This can initially isolate a concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can be caused by damaged or worn tire and wheels.
Perform a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout.
Refer to the tire wear chart to determine the tire wear conditions and actions
WHEEL AND TIRE DIAGNOSIS
Rapid wear at the center
• Center-tread down to fabric due to
excessive over inflated tires
• Lack of rotation
• Excessive toe on drive wheels
• Heavy acceleration on drive
Partial wear
• Caused by irregular burrs on brake drums
Suspension System
Components Location
[Front Suspension]
Rapid wear at both shoulders
• Under-inflated tires
• Worn suspension components
• Excessive cornering speeds
• Lack of rotation
Feathered edge
• Toe adjustment out of specification
• Damaged or worn tie rods
• Damaged knuckle
Wear at one shoulder
• Toe adjustment out of specification
• Camber out of specification
• Damaged strut
• Damaged lower arm
Wear pattern
• Excessive toe on non-drive wheels
• Lack of rotation
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1. Drive shaft
2. Lower arm
3. Front axle
4. Front strut assembly
[Power Electric Frame]
5. Stabilizer bar
6. Steering gear box
7. Sub frame
8. Front stabilizer link
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1. Power Electric Frame
Suspension System
Components
Page 26 sur 115
1. Strut assembly
2. Insulator
3. Strut bearing
4. Spring upper pad
Suspension System
Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque:
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
5. Coil spring
6. Dust cover
7. Bumper rubber
8. Spring lower pad
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• Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3. Loosen the bolts (A, B), and then remove the wheel speed sensor.
Tightening torque:
6.8 ~ 10.7N.m (0.7 ~ 1.1kgf.m, 5.0 ~ 7.9lb-ft)
4. Loosen the brake hose bracket bolts (A).
Tightening torque:
8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)
5. Disconnect the stabilizer link (A) from the front strut assembly after loosening the nut (B).
Tightening torque:
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3~86.8lb-ft)
6. Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
7. Disconnect the front strut assembly (A) from the knuckle by loosening the bolt & nut.
Tightening torque:
137.3 ~ 156.9N.m(14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)
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8. Remove the front strut assembly and then loosen the strut mounting nuts (A).
Tightening torque:
44.1 ~ 58.8N.m(4.5 ~ 6.0kgf.m, 32.5~43.4lb-ft)
9. Installation is the reverse of removal.
Disassembly
1. Using the special tool (09546-26000), compress the coil spring (A).
Tightening torque:
58.8 ~ 68.6N.m(6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)
2. Remove the self-locking nut (C) from the strut assembly (B).
3. Remove the insulator, spring seat, coil spring and dust cover from the strut assembly.
4. Reassembly is the reverse of the disassembly.
Inspection
1. Check the strut bearing for wear and damage.
2. Check the spring upper and lower seat for damage and deterioration.
3. Compress and extend the piston rod (A) and check that there is no abnormal resistance or unusual sound during operation.
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Disposal
1. Fully extend the piston rod.
2. Drill a hole on the (A) section to remove gas from the cylinder.
• The gas coming out is harmless but be careful of chips that may fly when drilling.
Suspension System
Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque:
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
• Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3. Remove the lower arm (A) from the knuckle.
Tightening torque:
58.9 ~ 70.6N.m (6.0 ~ 7.2kgf.m, 43.4 ~ 52.1lb-ft)
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4. Loosen the bolts (B,C), and then remove the front lower arm (A).
Tightening torque
(B) 117.7 ~ 137.3N.m(12.0 ~ 14.0kgf.m, 86.8 ~ 101.3lb-ft)
(C) 156.9 ~ 176.5N.m(16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
5. Installation is the reverse of removal.
Inspection
1. Check the bushing for wear and deterioration.
2. Check the front stabilizer bar for deformation.
3. Check the all bolts and nuts.
Suspension System
Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.
Tightening torque:
32.4 ~ 37.3N.m (3.3 ~ 3.8kgf.m, 23.9 ~ 27.5lb-ft)
Insert to the shaft in order that the center of the bolt and the marking (A) is in a straight line.
3. Remove the front wheel and tire (A) from front hub.
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Tightening torque:
88.2 ~ 107.8N.m (9.0 ~ 11.0kgf.m, 65.0 ~ 79.5lb-ft)
• Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
4. Remove the stabilizer link (A) loosening the nut.
Tightening torque:
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3~86.8lb-ft)
5. Remove the tie rod end ball joint (C) from the knuckle by using the SST (09568-34000).
(1) Remove the split pin (A).
(2) Remove the castle nut (B).
(3) Use the SST (09568-34000).
Tightening torque:
23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 19.4 ~ 24.6lb-ft)
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• When using SST, be sure not to damage the dust cover of lower arm ball joint.
• Keep SST tied to the car because there is a risk of injury by dropping the SST during removing the lower arm ball joint.
• The peripheral parts may be damaged when removing the lower arm ball joint with a general tool such as lever, so be sure to
use SST.
6. Loosen the bolt & nut and then remove the lower arm (A).
Tightening torque:
58.9 ~ 70.6 N.m (6.0 ~ 7.2 kgf.m, 43.4 ~ 52.1 lb-ft)
7. Loosen the bolt and then separate the roll rod stopper (A).
Tightening torque:
107.9 ~127.5N.m(11.0 ~ 13.0kgf.m, 79.6 ~ 94.0lb-ft)
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8. Install the jack and then remove the bolt and nut.
Tightening torque
Sub frame mounting bolts & nuts :
156.9 ~ 176.5N.m(16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
9. Remove the stabilizer (A) from the front sub frame by loosening the mounting bolts & nuts.
Tightening torque:
44.1 ~ 53.9N.m(4.5 ~ 5.5kgf.m, 32.5 ~ 39.8lb-ft)
10. Install in the reverse order of removal.
11. Check the wheel Alignment.
(Refer to Tires/Wheels - "Alignment")
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Inspection
1. Check the bushing for wear and deterioration.
2. Check the front stabilizer bar for deformation.
Suspension System
Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
• Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
3. Remove the stabilizer link (A) loosening the nut.
Tightening torque :
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3~86.8lb-ft)
4. Install in the reverse order of removal.
Suspension System
Replacement
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1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.
Tightening torque:
32.4 ~ 37.3N.m (3.3 ~ 3.8kgf.m, 23.9 ~ 27.5lb-ft)
Insert to the shaft in order that the center of the bolt and the marking (A) is in a straight line.
3. Remove the front wheel and tire (A) from front hub.
Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
• Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
4. Remove the stabilizer link (A) loosening the nut.
Tightening torque :
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3~86.8lb-ft)
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5. Remove the tie rod end ball joint (C) from the knuckle by using the SST (09568-34000).
(1) Remove the split pin (A).
(2) Remove the castle nut (B).
(3) Use the SST (09568-34000).
Tightening torque:
23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 19.4 ~ 24.6lb-ft)
• When using SST, be sure not to damage the dust cover of lower arm ball joint.
• Keep SST tied to the car because there is a risk of injury by dropping the SST during removing the lower arm ball joint.
• The peripheral parts may be damaged when removing the lower arm ball joint with a general tool such as lever, so be sure to
use SST.
6. Loosen the bolt & nut and then remove the lower arm (A).
Tightening torque :
58.9 ~ 70.6 N.m (6.0 ~ 7.2 kgf.m, 43.4 ~ 52.1 lb-ft)
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7. Loosen the bolt and then separate the roll rod stopper (A).
Tightening torque :
107.9 ~127.5N.m(11.0 ~ 13.0kgf.m, 79.6 ~ 94.0lb-ft)
8. Install the jack and then remove the bolt and nut.
Tightening torque
Sub frame mounting bolts & nuts :
156.9 ~ 176.5N.m(16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
9. Remove the stabilizer (A) from the front sub frame by loosening the mounting bolts & nuts.
Tightening torque:
44.1 ~ 53.9N.m(4.5 ~ 5.5kgf.m, 32.5 ~ 39.8lb-ft)
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10. Remove the gear box (A) from the front sub frame by loosening the mounting bolts.
Tightening torque:
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 43.4 ~ 57.9lb-ft)
11. Remove the front lower arm.
(Refer to Front Suspension System - "Front Lower Arm")
12. Installation is the reverse of removal.
13. Check the wheel Alignment.
(Refer to Tires/Wheels - "Alignment")
Suspension System
Removal
1. Remove the motor & gear drive unit.
(Refer to Traction Motor System - "Motor & Gear Differential Unit Assembly")
2. Remove the Electric Water Pump (EWP).
(Refer to Traction Motor System - "Electric Water Pump")
3. Remove the accumulator mounting bolt (A).
Tightening torque :
6.8 ~ 10.7 N.m(0.7 ~ 1.1 kgf.m, 5.0 ~ 7.9 lb-ft)
4. Remove the wiring (A) from the power electric frame.
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5. Remove the LH & RH support bracket mounting nut (A,B) and then remove the Power Electric Frame (A).
Tightening torque
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
6. Install in the reverse order of removal.
Suspension System
Components Location
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1. Torsion beam axle
2. Shock absorber
Suspension System
Components
3. Coil spring assembly
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1. Shock absorber assembly
2. Dust cover
3. Bump stopper
4. Cup
5. washer
6. Insulator assembly
7. Lock nut
Suspension System
Replacement
1. Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
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• Be careful not to damage to the hub bolts when removing the rear wheel and tire (A).
3. Loosen the rear shock absorber (A) upper mounting bolt.
Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)
4. Loosen the bolt and then remove the rear shock absorber (A) from the torsion beam axle.
Tightening torque :
98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)
Inspection
1. Check the rubber parts for wear and deterioration.
2. Compress and extend the piston rod (A) and check that there is no abnormal resistance or unusual sound during operation.
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Disposal
1. Fully extend the piston rod.
2. Drill a hole on the (A) section to remove gas from the cylinder.
• The gas coming out is harmless but be careful of chips that may fly when drilling.
Suspension System
Components
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1. Spring lower pad
2. Spring
3. Spring upper pad
Suspension System
Replacement
1. Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
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• Be careful not to damage to the hub bolts when removing the rear wheel and tire (A).
3. Loosen the bolt and then remove the rear shock absorber (A) from the torsion beam axle.
Tightening torque :
98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)
4. Disconnect the eletric parking brake acturator connector.
5. Remove the bolt (A) and then remove the fastener (B) and wheel speed sensor cable from the fixed bracket.
6. Pull the torsion beam axle in the direction of a down and then remove the coil spring (A).
7. Installation is the reverse of removal.
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Inspection
1. Check the coil spring for crack and deformation.
2. Check the coil spring pad for damage and deformation.
Suspension System
Components
1. Rear torsion beam axle
Suspension System
Replacement
1. Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.
2. Remove the front wheel and tire (A) from front hub.
Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
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• Be careful not to damage to the hub bolts when removing the rear wheel and tire (A).
3. Loosen the guide rod bolt (B) and the remove the rear caliper body (A).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
4. Remove the pads (B), in the caliper carrier (A).
5. Remove the brake caliper mounting bolts (B), and then place the brake caliper assembly (A) with wire.
Tightening torque :
63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)
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6. Disconnect the wheel speed sensor connector (A).
7. Loosen the screws (B), and then remove the brake disc (A).
Tightening torque:
4.9 ~ 5.8 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
8. Loosen the bolts and then remove the hub bearing (A).
Tightening torque:
58.8 ~ 68.6 N.m (6.0 ~ 7.0 kgf.m, 43.3 ~ 50.6 lb-ft)
9. Remove the hub bearing by using the rubber hammer.
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10. Loosen the rear shock absorber (A) upper mounting bolt.
Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)
11. Loosen the bolt and then remove the rear shock absorber (A) from the torsion beam axle.
Tightening torque :
98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)
12. Remove the bolt (A) and then remove the fastener (B) and wheel speed sensor cable from the fixed bracket.
13. Pull the torsion beam axle in the direction of a down and then remove the coil spring (A).
Tightening torque :
98.1 ~ 117.7 N.m(10.0 ~ 12.0 kgf.m, 72.3 ~ 86.8 lb-ft)
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14. Loosen the mounting bolts (B) and then remove the torsion beam axle (A) from the frame.
Tightening torque :
98.1 ~ 117.7 N.m(10.0 ~ 12.0 kgf.m, 72.3 ~ 86.8 lb-ft)
15. Installation is the reverse of removal.
• Use a SST(09581-11000) when installing the brake caliper assembly.
Inspection
1. Check the hub for cracks and the splines for wear.
2. Check the rear axle carrier for cracks.
Suspension System
Tire Wear
1. Measure the tread depth of the tires.
Tread depth [limit] :1.6 mm (0.0630 in.)
2. If the remaining tread depth (A) is less than the limit, replace the tire.
When the tread depth of the tires is less than 1.6 mm(0.063 in), the wear indicators (B) will appear.
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Tire Rotation
Checking For Pull And Wander
• Using tires and wheel other than the recommended sizes could cause unusual handling characteristics and poor vehicle control,
resulting in a serious accident.
If the steering pulls to one side, rotate the tires according to the following wheel rotation procedure.
1. Rotate the front right and front left tires, and perform a road test in order to confirm vehicle stability.
2. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test again.
3. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a road test.
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4. If the steering continues to pull to the opposite side, replace the front wheels with new ones.
Removal
• Using tires and wheel other than the recommended sizes could cause unusual handling characteristics and poor vehicle control,
resulting in a serious accident.
1. Remove valve core and deflate the tire.
2. Remove the side of the tire bead area from the wheel using tire changing machine .
• The tire bead should be broken approx. 90° from the valve side of the wheel. The bead breaker should not be set too deep.
• Avoid tire/tool contact with the valve on dismount.
• Dismount should end near the valve.
3. Rotate the wheel clockwise.
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Installation
1. Apply tire soap or lubrication to the top and bottom tire beads.
2. To fit the bottom bead, position the valve at the 5 o’clock position relative to the head on the tire changing machine.
3. Place the tire on the rim so the bottom bead touches the edge of the rim after the valve (6 o’clock). Rotate the rim clockwise, and push
down on the tire at the 3 o’clock position to fit bottom bead.
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4. After bottom bead is on tire, rotate the rim until the valve is at the 5 o’clock position relative to the head on the tire changing machine.
Push down on the tire at the 3 o’clock position and rotate the rim clockwise to fit the top bead.
5. Inflate the tire until both beads seat.
Tire pressure :2.3kg/cm² (33psi)
Suspension System
Hub nut tightening sequence
Tighten the hub nuts as follows.
Tightening torque:
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
When using an impact gun, final tightening torque should be checked using a torque wrench.
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Run out inspection
1. Jack up the vehicle.
2. Measure the wheel Run-out by using a dial indicator as illustration below.
Run-out
Aluminum
Radial mm(in.)
Below 0.3(0.0118)
Lateral mm(in.)
Below 0.3(0.0118)
3. If measured value exceeds the standard value, replace the wheel.
Suspension System
Front wheel alignment
When using a commercially available computerized wheel alignment equipment to inspect the front wheel alignment, always position
the vehicle on a level surface with the front wheels facing straight ahead.
Prior to wheel alignment, steering column is approximately in tilt mid position.
Toe
B - A > 0: Toe in (+)
B - A ＜ 0: Toe out (-)
Toe adjustment
1. Loosen the tie rod end lock nut.
2. Remove the bellows clip to prevent the bellows from being twisted.
3. Adjust the toe by screwing or unscrewing the tie rod. Toe adjustment should be made by turning the right and left tie rods by the same
amount.
Toe-in
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Total : 0.1° ± 0.2°
Individual : 0.05° ± 0.1°
4. When completing the toe adjustment, install the bellows clip and tighten the tie rod end lock nut to specified torque.
Tightening torque:
49.0 ~ 53.9 N.m (5.0 ~ 5.5 kgf.m, 36.2 ~ 39.8 lb-ft)
Camber and Caster
Camber and Caster are pre-set at the factory, so they do not need to be adjusted. If the camber and caster are not within the standard value,
replace or repair the damaged parts and then inspect again.
Camber angle: -0.5° ± 0.5°
Caster angle: 5.7.° ± 0.5°
Suspension System
Components
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1. TPMS Receiver
2. TPMS Sensor (FL)
3. TPMS Sensor (RL)
Suspension System
Circuit Diagram
4. TPMS Sensor (RR)
5. TPMS Sensor (FR)
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Hamess Connector
Pin No.
Description
1
BATT+
2
IG_ON
3
CAN_L
4
CAN_H
5
NC
6
GND
Suspension System
Description
TREAD Lamp
- Tire Under Inflation / Leak Warning.
1. Turn on condition
A. When tire pressure is below allowed threshold
B. When rapid leak is detected by the sensor.
C. Indicates that tire needs to be re-inflated to placard pressure / repaired.
2. Turn off condition
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A. Under-inflation ; When tire pressure is above (warning threshold + hysteresis).
B. Rapid Leak ; When tire pressure is above (leak warning threshold).
DTC Warning
1. Turn on condition
A. When the system detects a fault that is external to the receiver/ sensor.
B. When the system detects a receiver fault.
C. When the system detects a sensor fault.
2. Turn off condition
A. If the fault is considered as 'critical', then the lamp is held on throughout the current Ignition cycle (even if the DTC has been
demoted). This is because it is important to bring the problem to the drivers attention. On the following Ignition cycle, the demotion
conditions will be re-checked. If the demotion conditions occur, the lamp will be turned off. It will be held on until DTC demotion
checking is completed.
B. 'Non critical' faults are those that can occur temporarily e.g. vehicle battery under voltage. The lamp is therefore turned off when the
DTC demotion condition occurs.
System Fault
1. General Function
A. The system monitors a number of inputs across time in order to determine that a fault exists.
B. Faults are prioritized according to which has the most likely cause.
C. Certain faults are not covered through DTC. The main ones are:
1) Sensor thermal shutdown (over 257°F/125°C).
2) Ignition Line stuck ; requires observation of lamps at Ignition ON to diagnose.
Suspension System
Description
Mode of Operation
ASIC Mode
1. Factory Mode
The factory mode is the mode that allows the TPM sensor to transmit RF Frames and sample LF more often in the HKMC factory. The
TPM sensor will send normal RF frames in factory mode.
LF sampling will occur every 1 second, to ensure a rapid response on the production line.
Figure 5 shows the state flow of the ASIC from Off mode through Factory mode to Non-Factory mode.
Factory mode is not a normal mode; it operates over the other customer visible modes to increase the LF sampling rates while the factory
counter is not Zero.
On leaving Off mode the factory counter will be set to 15, each time the sensor moves from Service mode to stationary mode, the counter
will be decremented.
After Factory mode has expired, the Factory_LF command can be used to re-enter Factory mode, in which case the factory counter will
be reset to 15.
If Factory mode is no longer required, it is possible to reset the factory counter, and therefore exit Factory mode by using the
Exit_Factory_LF command.
During 10.8s mode, the sensor will transmit normal RF data frames every 10.8s. In case of high line sensor, the function code will
indicate rotational direction.
Mode
Pressure Sample Rate
(seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample
Rate (seconds)
Normal Tx Rate (Seconds)
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Factory
10.8
10.8
10.8
10.8
2. Stationary Mode
In normal operation and while the vehicle is not moving the TPM Sensor will be in STATIONARY mode. In this mode sample and
transmission rates are described below.
Mode
Pressure Sample Rate
(seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample
Rate (seconds)
Normal Tx Rate (Seconds)
Non-factory
60
60
15
-
Factory
60
60
15
-
STATIONARY mode is excited when the vehicle begins to move and shock sensor input is verified by the ASIC.
3. AL/ALO Mode
Upon detection of motion, an Unknown / Normal function code is transmitted, then the sensor enters AL Mode (Auto Learn Mode) or ALO
Mode (Auto Location Mode), depending on TPM sensor type (Lowline or Highline).
During AL mode, the sensor will continue to transmit Unknown/Normal function codes every 33 seconds for a duration of 16 RF Blocks
( 1 RF block = 4 RF frames).
During ALO mode the TPM sensor begins to determine which direction the sensor is rotating – clockwise or anticlockwise. For the first
transmission after the Unknown / Normal function code, the data block will contain one of three function codes for ALO Mode. If the ASIC
is unable to make a decision concerning rotational direction, then the sensor shall transmit an Unknown / Normal function code.
During AL/ALO Mode the shock sensors are sampled for motion, every 10.8 seconds. The pressure and temperature samples also occur
every 10.8 seconds. The transmission rate and duration of AL/ALO Mode is set to a one block transmission (4 frames) rate every 33
seconds for a duration of 16 blocks. In ALO Mode rotational direction is acquired every 10.8 seconds. The transmitted function code is
based on all ALO data since its last transmission.
The AL/ALO mode function flag will be set for the transmission of all valid AL/ALO frames.
If the speed of the vehicle drops below the stationary threshold and the sensor detects that there is no motion present, then AL/ALO
Mode will be exited and Service Mode will be entered. If Service Mode exits due to detection of motion and AL/ALO Mode is re-entered
then the AL/ALO Mode continues where it left off i.e. the total AL/ALO duration of 16 blocks is achieved regardless if Service Mode or
Alert Mode has been entered during that AL/ALO Mode.
If a pressure change (Alert Mode) is detected in AL/ALO Mode and DP transmissions occur, AL/ALO Mode is suspended until the DP
transmissions finish.
Sensors with ALO mode have 4 configurable options to optimize the WAL performance based on evaluation with the customer. Sensors
supplied to Hyundai/Kia will have option 2 configured.
Mode
Pressure Sample Rate
(seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample
Rate (seconds)
Normal Tx Rate (Seconds)
Non-factory
10.8
10.8
10.8
33
Factory
10.8
10.8
10.8
33
4. Service Mode
Service Mode is the period when the TPM sensor has detected that the vehicle speed has dropped below the stationary threshold.
During this period the pressure and temperature and motion samples occur every 15 seconds but there are no transmissions, the TPM
sensor will only transmit on a pressure change, DP. The DP transmission will consist of two blocks (Total of 8 frames) of pressure
information transmitted over a two second period. The duration of Service Mode is 15 minutes from when the TPM sensor has detected
that there is no rolling detection. If during Service Mode rolling detection is detected again, the sensor will exit Service Mode and re-enter
the mode it was previously in before it entered Service Mode, AL Mode or Normal Mode. Every time Service Mode is entered the 15minute timer is reset. If Service Mode is exited before the Service Mode timer expires then the AL Mode counter will not be reset. Upon
expiration of Service Mode the AL Mode counter is reset.
Mode
Pressure Sample Rate
(seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample
Rate (seconds)
Normal Tx Rate (Seconds)
Non-factory
15
15
15
-
Factory
15
15
15
-
5. Rolling Mode
When AL Mode expires the TPM sensor enters Rolling Mode. In Rolling Mode the rate of transmissions and rolling detection sampling
are decreased to once every 60s and the rate of pressure and temperature sampling occur every 15 seconds. For the first 16 blocks of
transmissions after a drive begins the TPM sensor transmits the AL Mode function codes Clockwise, Anticlockwise or Normal/Unknown.
After the 16 blocks of AL information have been transmitted, the TPM sensor will transmit the Normal/Unknown function code. If the
speed of the vehicle drops below the stationary threshold and the TPM sensor detects that there is no rolling detection present, then
Rolling Mode will be suspended and Service Mode will be entered.
On entry to Rolling mode the TPM sensor will sample pressure and do a normal RF transmission with a NORMAL/UNKOWN function
code (see 4.1.1.5: Status Byte).
Mode
Pressure Sample Rate
(seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample
Rate (seconds)
Normal Tx Rate (Seconds)
Non-factory
15
15
60
60
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Factory
15
15
60
60
When vehicle speed has dropped below minimum vehicle speed threshold, the sensor will remain in Rolling mode until the next
scheduled rolling detection sample occurs. Once the rolling detection sample has confirmed the vehicle speed is below the threshold, the
TPM sensor will enter Service Mode. After the Service Mode period has elapsed the TPM sensor will exit to STATIONARY Mode.
6. Alert Mode
In Stationary mode, Service Mode or Rolling mode, pressure is measured at intervals as described above. During the measurement
routine the current pressure value is compared to the previous transmitted pressure value. If the current pressure sample differs by
greater than 8 counts (>2 psi ) or more from the previous transmitted pressure value, a RE-MEASURE will occur immediately to ensure
the sample is correct. If a delta P is confirmed the TPM Sensor will transmit immediately with an Alert status code. If the RE-MEASURE
transmission occurs coincident with a regular transmission, the RE-MEASURE takes precedence and the regular transmission will be
replaced by the RE-MEASURE transmission.
(1) Stationary Alert Mode
While the sensor is in Stationary Mode, it shall transmit an instantaneous measured data frame, as defined in Section 4.1 of this
document, if a pressure change of 2.0 psi from the last transmission or greater has occurred. All transmissions occurred due to a
pressure change event shall have the Alert status code as specified in Section 4.1.1.5.6.
Stationary Alert mode will be exited if a change in pressure of 2.0p.s.i. or greater is not detected after 2 consecutive pressure
samples.
Pressure Sample Rate
(seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample Rate
(seconds)
Normal Tx Rate (Seconds)
2 (max)
2 (max)
N/A
ΔP
(2) While the sensor is in Rolling Mode, it shall transmit an instantaneous measured data frame, as defined in Section 4.1 of this
document, if a pressure change of 2.0p.s.i. or greater from the last transmission or greater has occurred All transmissions occurred
due to a pressure change event shall have the Alert status code as specified in Section 4.1.1.5.6.
Rolling Alert mode will be exited if a change in pressure of 2.0p.s.i. or greater is not detected after 2 consecutive pressure samples.
Pressure Sample Rate
(seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample Rate
(seconds)
Normal Tx Rate (Seconds)
2 (max)
2 (max)
N/A
ΔP
7. OFF Mode
This is a mode primarily used for shipping and storage of the TPM sensor units. When the sensor is de-energized (using the Enter_Off
LF command), it shall transmit one last transmission with the Off Mode function code then enter the Off Mode immediately. When the
TPM sensor is in Off Mode, it shall continue sampling pressure and temperature at the rate specified in Table 13 of this document but it
shall not transmit any transmission until the TPM sensor is re-energized again.
The TPM sensor can be re-energized using the Normal LF command or when it detects a change in pressure of 19p.s.i. or greater.
Pressure Sample Rate (seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample Rate
(seconds)
Normal Tx Rate (Seconds)
60(max)
60 (max)
-
-
8. RF Test Mode
The sensor must enter the RF Test Mode and provide the state code specified in 4.1.1.5.6of this document upon the presence of an LF
signal with the LF data command “Test_LF” specified in Table 16 below.
The sensor must react (Transmit and provide data) no later than 700.0 ms after the LF data code has been detected. As soon as the
sensor enters this mode it shall comply with all the sampling and transmission requirements specified in Table 14 of this document,
regarding this specific mode independent of rotating, stationary, or service mode.
The sensor shall count the number of frames (each transmission contains four frames as shown in Table 15 of this document) it has
transmitted since it entered this Mode, and this number shall be transmitted within the data in each frame as shown in Table 15 below.
The Data transmitted shall be in the format shown in Table 15 below. When the counter for the number of frames reach the value 255 (All
of the 8 bits are used), the counter shall reset and restart again until the sensor exits this mode.
When the sensor exits this mode it shall clear the number of frames counter. The sensor shall exit this mode upon the presence of a
Normal_LF command as specified in Section 3.3.2 of this document.
The sensor shall start an eight hours timer from the moment it enters this mode and then shall exit this Mode immediately after the eight
(8.0) hours' timer expires
Pressure Sample Rate (seconds)
Temperature Sample Rate
(seconds)
Rolling detection Sample Rate
(seconds)
Normal Tx Rate (Seconds)
15(max)
15(max)
15(max)
15(max)
RF Test Mode Data Structure = Fram 1 = Fram 2 = Fram 3 = Fram 4
Preamble
H/L Bit
ID
Pressure
No. of Frames
Status
CRC
16 bits
1 bit
31 bits
8 bits
8 bits
8 bits
8 bits
9. Continuous Wave (CW) Mode
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The TPM sensor must enter the specified CW Mode when it receives the appropriate LF data command ( CW_Low_LF or
CW_High_LF ).
The TPM sensor must react (Transmit) no later than 200.0 ms after the LF data code has been detected. As soon as the sensor enters
this mode it shall start transmitting the specified CW frequency (Carrier Wave Frequency) of the TPM sensor.
There are 2 CW modes available:
A. CW Low will transmit continuously at the lower FSK frequency.
B. CW High will transmit continuously at the upper FSK frequency.
The sensor shall exit this mode upon the presence of a Normal_LF command.
The sensor shall start a four minutes timer from the moment it enters this mode and then shall exit this Mode immediately after the four
(4.0) minutes timer expires.
Suspension System
Removal
1. Remove the tire.
(Refer to Tires/Wheels - "Tire")
2. Remove the screw with torx driver (A).
• When installing the bead brake, make sure that it does not come in contact with the TPMS sensor.
• Be careful not to damage the TPMS sensor when installing the bead brake near the TPMS sensor.
3. Remove the sensor body (A) from the valve (B) in the direction of the arrow.
4. Use the valve mounting tool to pull out the valve until it is entirely out of the lower hole.
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Cut the rubber at the bottom of valve with a knife.
5. Apply lubricant to the surface of the valve, and then mount it through the valve hole of the wheel.
We recommend using regular soapy water as lubricant.
• The TPMS sensor valve bottom is not properly sealed if it is not fully mounted on the wheel, as shown in the following figure:
• Make sure that the valve body is pulled entirely through the hole.
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6. Apply soapy water or lubricant to the upper/lower bead section of the tire.
7. In order to mount lower the beads, place the TPMS sensor at 5 o'clock, starting from the head of the tire replacement equipment.
8. Rotate the rim clockwise and press tire towards 3 o'clock to mount the lower beads.
• Mount the tire on the wheel. Make sure that the beads touch the edge of the rim behind the sensor (towards 6 o'clock).
9. In order to mount the upper beads, press the tire towards 3 o'clock and turn the rim clockwise.
10. Inject air into the tire until the beads are in the correct position.
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11. Adjust the tire pressure according to the recommended tire pressure for the vehicle.
12. If the TPMS sensor malfunctions, you must perform TPMS sensor learning. Replace any faulty sensors and perform TPMS sensor
learning.
Diagnosis procedure by using diagnostic device
As manual for diagnosis methods by using diagnosis device, the main contents are as follows:
1. Connect self-diagnosis connector(16pins) located in the lower of driver side crash pad to self-diagnosis device, and then turn the selfdiagnosis device after key is ON.
2. Select the "vehicle model" and "TPMS" on GDS vehicle selection screen, then select OK.
[System Identification (Wireless)]
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[Sensor ID Writing (Wireless)]
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[VIN input initialization]
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[Vehicle name input initialization]
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[Sensor Status initialization]
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[Register Sensor initialization]
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• Write ID Read ID and be sure to check are the same.
• After registering successfully sensor "Sensor Wireless Information" by the execution determines whether the sensor is working
properly.
Suspension System
Description
1. Mode
(1) Virgin State
A. The receiver as a sole part is shipped in this state. Replacement parts should therefore arrive in this state.
B. In this state, there is no sensor monitoring and no DTC monitoring.
C. The state indicates that platform specific parameters must be written to the receiver and that sensors are un-learned.
(2) Normal State
A. In order for tire inflation state and DTC monitoring to occur, the receiver must be in this state.
B. In this state, automatic sensor learning is enabled.
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(3) Test State
A. This state is only used in manufacturing plant to check RF transmission between sensor and receiver.
2. Overview
A. Receives RF data from sensor.
B. Uses sensor data to decide whether to turn on TREAD Lamp.
C. Learn TPM sensor for under inflation monitoring automatically.
D. Uses sensor information, distance travelled, background noise levels, Auto-learn status, short / open circuit output status, vehicle
battery level, internal receiver states to determine if there is a system or a vehicle fault.
Operation
1. General Function
A. Auto-learn takes place only once per Ignition cycle.
B. On successful completion, 4 road wheel sensor ID's are latched into memory for monitoring.
C. Until Auto-learn completes, previously learned sensors are monitored for under inflation / leak warnings.
2. General Conditions to Learn New Sensors:
A. Receiver must determine that it is confident that sensor is not temporary:
1) Uses vehicle speed.
2) Uses confidence reduction of previously learned sensors.
B. Typical time at driving continuously over 15.5 mph(25 kph) to learn a new sensor is up to 20 minutes.
3. General Conditions to Un-Learn a sensor that is removed:
A. It takes less than 20 minutes at 15.5 mph(25 mph).
B. Confidence reduction is dependent on time which vehicle is driven at speed greater than or equal to 12.4 mph(20 kph).
Suspension System
Replacement
When the receiver first arrives for replacement:
1) It will be in Virgin State.
2) It will not be configured for any specific platform.
3) It will not have any sensor ID's memorized.
It is important to make sure that the correct receiver is used to replace the faulty part i.e. it must be Low Line and not High Line in order
to have the correct inflation warning thresholds set.
1. Disconnect vehicle battery.
2. Remove the crash pad garnish.
(Refer to BD group - "Crash Pad")
3. Remove the receiver with bracket.
4. Install in the reverse order of removal.
5. Re-connect battery and turn Ignition on.
6. After replacing the receiver, learn by using self-diagnosis device(GDS).
[Wheel Sensor ID Writing (Wireless) initialization]
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[Wheel Sensor ID Writing (Wireless) 1]
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[Wheel Sensor ID Writing (Wireless) 2]
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Diagnosis procedure by using diagnostic device
As manual for diagnosis methods by using diagnosis device, the main contents are as follows:
1. Connect self-diagnosis connector(16pins) located in the lower of driver side crash pad to self-diagnosis device, and then turn the selfdiagnosis device after key is ON.
2. Select the "vehicle model" and "TPMS" on GDS vehicle selection screen, then select OK.
[System Identification (Wireless)]
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[Sensor ID Writing (Wireless)]
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[VIN input initialization]
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[Vehicle name input initialization]
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[Sensor Status initialization]
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[Register Sensor initialization]
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• Write ID Read ID and be sure to check are the same.
• After registering successfully sensor "Sensor Wireless Information" by the execution determines whether the sensor is working
properly.
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Steering System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Steering System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Steering System
Specifications
Item
Type
Steering gear
Specification
MDPS(Motor Driven Power Steering)
Type
Rack & Pinion
Rack stroke
Steering angle (Max.)
154 ± 1mm
Inner
37.6° (+0.5°/-1.5°)
Outer
31.3°
Tightening Torques
Item
Wheel Hub nuts
Tightening torque (kgf.m)
Nm
kgf.m
lb-ft
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
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Steering wheel lock nut
39.2 ~ 49.0
4.0 ~ 5.0
28.9 ~ 36.2
Steering column bolt. (to universal joint)
28.9 ~ 36.2
5.0 ~ 6.0
58.8 ~ 70.6
Steering column mounting nuts
24.5 ~ 29.4
2.5 ~ 3.0
18.1 ~ 21.7
Steering column mounting bolt
44.1 ~ 49.0
4.5 ~ 5.0
32.5 ~ 36.2
Bolt connecting universal joint bolt. (to pinion)
32.4 ~ 38.3
3.3 ~ 3.8
23.9 ~ 27.5
Tie rod end castle nut
23.5 ~ 33.3
2.4 ~ 3.4
17.4 ~ 24.6
Lower arm ball joint bolt & nut (to knuckle)
58.8 ~ 70.6
6.0 ~ 7.2
43.4 ~ 52.1
Steering gear box mounting bolt. (to sub frame)
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Sub frame mounting bolts & nuts
156.9 ~ 176.5
16.0 ~ 18.0
115.7 ~ 130.2
Stabilizer bar nut ( to stabilizer link)
98.1 ~ 117.7
10.0 ~ 12.0
72.3 ~ 86.8
Steering System
Special Service Tools
Tool Name / Number
Illustration
Description
Steering wheel puller
09561-11001
Remove the steering wheel
Ball joint puller
09568-34000
Separate the ball joint from the front axle.
Steering System
Inspection
Steering Wheel Play Inspection
1. Turn the steering wheel so that the front wheels can face straight ahead.
2. Measure the distance the steering wheel can be turned without moving the front wheels.
Standard value:30mm (1.18in.) or less
3. If the play exceeds standard value, inspect the steering column, shaft, and linkages.
Checking stationary steering effort
1. Position the vehicle on a level surface and place the steering wheel in the straight ahead position.
2. Attach a spring scale to the steering wheel. With the engine speed 900 ~ 1100rpm, pull the scale and read it as soon as the tires begin to
turn.
Standard value:3.0kgf or less
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3. If the measured value exceeds standard value, inspect the power steering gear box and MDPS system.
Steering System
Components
1. Steering column assembly
2. Universal joint assembly
3. Steering gear box
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Steering System
Schematic Diagrams
MDPS Circuit Diagram
Harness Connector
Connector
Battery
Vehicle signal
Pin No.
Pin Name
1
Battery +
2
Battery -
1
Ignition
2
N.C.
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3
N.C.
4
N.C.
5
N.C.
6
N.C.
7
CAN_High
8
CAN_Low
Steering System
Description
EPS (Electric power steering, Column assist type) system uses an electric motor to assist the steering force and it is an engine operation
independent steering system.
EPS control module controls the motor operation according to information received from the each sensor and CAN (Controller Area
Network),
resulting in a more precise and timely control of steering assist than conventional engine-driven hydraulic systems. Components (Steering
Angle Sensor, Torque Sensor, Fail-safe relay, etc.) of the EPS system are located inside the steering column. EPS unit assembly, steering
column, and EPS unit assembly must not be disassembled for inspection. They must be replaced if necessary.
Note With Regard to diagnosis
Trouble factor
Check item
Drop, impact, and overload Motor
Trouble symptom
Explanation
Note
Abnormal noise
- Visable or invisible
- Do not use the impacted
damage can occur.The
EPS.- Do not overload
steering wheel could pull to each parts.
Circuit damage- Wrong
one side by using the
welding point- Broken PCB- dropped parts.- Precise
Damaged precise parts
parts of motor/ECU are
sensitive to vibration and
impact.- Overload can
cause unexpected damage
ECU
Torque sensor
Insufficient steering effort
Overload to INPUT shaft
can cause malfunction of
the torque sensor
Shaft
Insufficient steering effort
(Uneven between LH and
RH)
Pull/Dent
Harness
- Malfunction-impossible
power operationMalfunction of EPS
Abnormal storage
temperature
Motor/ECU
Abnormal steering effort by - Waterproof at the normal
improper operation of the condition- Even a little
motor/ECU
moisture can cause
malfunction of the precise
parts of the motor/ECU
- Do not impact the
connecting parts (When
inserting and torquing)Use the specified tool to
remove the steering wheel.
(Do not hammer on it)- Do
not use the impacted EPS
Do not use the impacted
EPS
Disconnection between
Do not overload the
harness connecting portion harness
and harness
- Keep the normal
temperature and proper
moisture, while storagingAvoid drowning
1. Do not impact the electronic parts, if they are dropped or impacted, replace them with new ones.
2. Avoid heat and moisture to the electronic parts.
3. Do not contact the connect terminal to avoid deformation and static electricity.
4. Do not impact the motor and torque sensor parts, if they are dropped or impacted, replace them with new ones.
5. The connector should be disconnected or connected with IG OFF.
Steering System
General Inspection
After or before servicing the EPS system, perform the troubleshooting and test procedure as follows. Compare the system condition with
normal condition in the table below and if abnormal symptom is detected, perform necessary remedy and inspection.
Test condition
IG Off
Normal condition: Motor must not supply steering assist.
Symptom
Motor supplies
steering assist.
Possible cause
Repair
ASP is not calibrated.
Perform the ASP calibration using a scan tool.
IG power supplies
Inspect the IG power supply line.
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Test condition
IG On/Engine Off
Test condition
IG On/Engine On
Normal condition: Motor must not supply steering assist, Warning lamp is illuminated.
Symptom
Motor supplies
steering assist.
Possible cause
Repair
ASP is not calibrated.
Perform the ASP calibration using a scan tool.
EMS CAN signal is not received.
Inspect the CAN line.
Warning lamp is not
Cluster fault
illuminated.
Inspect the cluster and cluster harness
Normal condition: Motor supplies steering assist, Warning lamp is not illuminated.
Symptom
Possible cause
Repair
Warning lamp is
illuminated and
Motor dose not
supply steering
assist.
Inspect the connector and harness for EPS (Hot
EPS (Hot at all times) and IG power supply fault
at all times) and IG power supply line.
DTC is detected by system.
Perform the self test using a scan tool and repair
or replace.
Warning lamp is
illuminated and
Motor supplies
steering assist.
ASP is not calibrated.
Perform the ASP calibration using a scan tool.
CAN communication between EPS and cluster is
Inspect the CAN line.
fault.
ASP: Absolute Steering Position
CAN: Controller Area Network
EMS: Engine Management System
The following symptoms may occur during normal vehicle operation and if there is no EPS warning light illumination, it is not malfunction
of EPS system.
• After turning the ignition switch on, the steering wheel becomes heavier while it performs EPS system diagnostics, for about 2
seconds, then it becomes normal steering condition.
• After turning the ignition switch on or off, EPS relay noise may occur but it is normal.
• When it is steered, while the vehicle is stopped or in low driving speed, motor noise may occur but it is normal operating one.
Caution when ASP (Absolute Steering Position) calibration or EPS type recognition
• Check if the battery is fully charged before ASP calibration or EPS type recognition.
• Be careful not to disconnect any cables connected to the vehicle or scan tool during ASP calibration or EPS type recognition.
• When the ASP calibration or EPS type recognition is completed, turn the ignition switch off and wait for several seconds, then start the
engine to confirm normal operation of the vehicle.
ASP Calibration
1. Select "Steering Angle Sensor".
2. Proceed with the test according to the screen introductions.
EPS Type Recognition Procedure
1. Select "EPS Variant Coding".
2. Proceed with the test according to the screen introductions.
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Steering System
Components
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1. Steering column assembly
2. Steering joint assembly
Steering System
Replacement
1. Disconnect the battery negative cable from the battery and then wait for at least 30 seconds.
2. Turn the steering wheel so that the front wheels can face straight ahead.
3. Remove the airbag module.
(Refer to Restraint - "Driver Airbag (DAB) Module and Clock Spring")
4. Disconnect the connector & lock nut (A) and then remove the steering wheel by using special service tools (09561-11001).
Tightening torque :
39.2 ~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft)
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• Do not hammer on the steering wheel to remove it; it may damage the steering column.
• Do not reuse lock nut.
• Must be replaced with new lock nut when assembling. (SEAL-LOCK has been processed)
5. Loosen the screw and then remove the steering column upper & lower shroud (A).
6. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel)
7. Disconnect the connectors (A) and then remove the clock spring (B).
8. Disconnect the connector (A).
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9. Loosen the screw and then remove the multifunction switches (A).
10. Loosen the bolt and then disconnect the universal joint assembly (A) from the pinion of the steering gear box.
Tightening torque :
32.4 ~ 37.3N.m (3.3 ~ 3.8kgf.m, 23.9 ~ 27.5lb-ft)
Insert to the shaft in order that the center of the bolt and the marking (A) is in a straight line.
11. Disconnect all connectors connected to the steering column.
12. Remove the steering column & EPS unit assembly by loosening the mounting bolt (B) and nuts (A).
Tightening torque :
Nut : 24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
Bolt : 44.1 ~ 49.0N.m (4.5 ~ 5.0kgf.m, 32.5 ~ 36.2lb-ft)
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13. Loosen the bolt (A) and then disconnect the universal joint assembly from the steering column assembly.
Tightening torque :
28.9 ~ 36.2 N.m (5.0 ~ 6.0 kgf.m, 58.8 ~ 70.6 lb-ft)
Must be ASP calibration and EPS type recognition after assembling.
Disassembly
Key lock assembly
1. Make a groove on the head of special bolts (A) by a punch.
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2. Loosen the special bolt using a screw driver and then remove the key lock assembly from the steering column assembly.
3. Reassembly is the reverse of the disassembly.
Inspection
1.
2.
3.
4.
Check the steering column for damage and deformation.
Check the joint bearing for damage and wear.
Check the tilt bracket for damage and cracks.
Check the key lock assembly for proper operation and replace it if necessary.
Steering System
Components
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1. Steering Gear box
Steering System
Replacement
1. Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2. Loosen the bolt and then disconnect the universal joint assembly (A) from the pinion of the steering gear box.
Tightening torque :
32.4 ~ 37.3N.m (3.3 ~ 3.8kgf.m, 23.9 ~ 27.5lb-ft)
Insert to the shaft in order that the center of the bolt and the marking (A) is in a straight line.
3. Remove the front wheel and tire (A) from front hub.
Tightening torque :
88.2 ~ 107.8N.m (9.0 ~ 11.0kgf.m, 65.0 ~ 79.5lb-ft)
Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
4. Remove the stabilizer link (A) loosening the nut.
Tightening torque :
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3~86.8lb-ft)
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5. Remove the tie rod end ball joint (C) from the knuckle by using the SST (09568-34000).
(1) Remove the split pin (A).
(2) Remove the castle nut (B).
(3) Use the SST (09568-34000).
Tightening torque :
23.5 ~ 33.3N.m(2.4 ~ 3.4kgf.m, 17.4 ~ 24.6lb-ft)
• When using SST, be sure not to damage the dust cover of lower arm ball joint.
• Keep SST tied to the car because there is a risk of injury by dropping the SST during removing the lower arm ball joint.
• The peripheral parts may be damaged when removing the lower arm ball joint with a general tool such as lever, so be sure to
use SST.
6. Loosen the bolt & nut and then remove the lower arm (A).
Tightening torque :
58.9 ~ 70.6 N.m (6.0 ~ 7.2 kgf.m, 43.4 ~ 52.1 lb-ft)
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7. Loosen the bolt and then separate the roll rod stopper (A).
Tightening torque :
107.9 ~127.5N.m(11.0 ~ 13.0kgf.m, 79.6 ~ 94.0lb-ft)
8. Loosen the bolts & nuts and then remove the sub frame (A).
Tightening torque :
Sub frame mounting bolt & nut
156.9 ~ 176.5N.m(16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
9. Remove the stabilizer (A) from the front sub frame by loosening the mounting bolts & nuts.
Tightening torque :
44.1 ~ 53.9N.m(4.5 ~ 5.5kgf.m, 32.5 ~ 39.8lb-ft)
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10. Remove the gear box (A) from the front sub frame by loosening the mounting bolts.
Tightening torque :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 43.4 ~ 57.9lb-ft)
11. Installation is the reverse of removal.
• Must be ASP calibration and EPS type recognition after assembling.
12. Check the wheel Alignment.
(Refer to Suspension System - "Alignment")
Steering System
Component
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1. Airbag module
2. Remote control upper switch
3. Remote control lower switch
4. Steering wheel assembly
5. Heated unit
6. Wiring
7. Steering wheel lower cover
Steering System
Replacement
1. Disconnect the battery negative cable from the battery and then wait for at least 30 seconds.
2. Turn the steering wheel so that the front wheels are facing straight ahead.
3. Remove the airbag module.
(Refer to Restraint - "Driver Airbag (DAB) Module and Clock Spring")
4. Disconnect the connector & lock nut (A) and then remove the steering wheel using the special service tool (09561-11001).
Tightening torque :
39.2 ~ 49.0N-m (4.0 ~ 5.0kgf-m, 28.9 ~ 36.2lb-ft)
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• Do not use a hammer when removing the steering wheel as it may damage the steering column.
• Do not reuse lock nuts.
• Lock nuts must be replaced with new ones when assembling. (SEAL-LOCK has been processed)
5. Install in the reverse order of removal.
Disassembly
1. Loosen the screw (A-6ea) and then remove the lower cover (B) from the steering wheel body.
2. Remove the wiring (A) & Heated unit (B).
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3. Remove the remote control upper switch assembly (A) and wiring.
4. Loosen the screw and then remote control switch assembly (A).
5. Installation is the reverse of the removal.
Steering System
Description
Heated pads in the steering wheel warm up the steering grip.
1. Heate control unit
2. Heated pad
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Specifications
Item
Specification
standard
minimum
Voltage
13.5 V
9V
16 V
Heated pad resistance
1.73Ω
1.56Ω
1.90Ω
NTC resistance
10.0 kΩ
9kΩ
11kΩ
Steering System
System Circuit Diagram
maximum
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Steering System
Inspection
1. Measure a resistance of NTC and Heated pad.
A. NTC resistance(Yellow / Black) - 10kΩ (9kΩ ~ 11kΩ), 25°C
B. Heated pad resistance (Yellow , Black) - 1.73Ω ( 2.1 ~ 2.5 Ω )
2. Measure a temperature.
A. The temperature of wheel surface grip must rise from -20°C to 20°C within 6 minute
B. The temperature of wheel surface grip must keep 38°C ± 4°C after 25 minute
C. Temperature measurement points (1~8)
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Steering System
Components Location
1. Flex steering swithch
Steering System
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Instruction
Flex Steer is system to choose the three modes power steering depending on driver preference or driving conditions.
• Display on the cluster but power steering is would not changed while operating the steering wheel.
As a safety measures, mode is changed automatically when steering wheel operation is done.
• Be sure to carefully change the mode while driving.
• Electric Power Steering (EPS) is not working due tofailure, "flex steer" may not work.
How to operate
• First input : Display the current mode on cluster. (4 seconds)
• Add input (4 seconds) : Mode is changed sequentially.
• Three steering modes
COMFORT : For the elder and the female drivers: it is mainly used for city driving and stop & parking, and a little lighter power steering.
NORMAL : Basic mode
SPORT : It is mainly used for highway driving, and a little heavy power steering.
Steering System
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the driver airbag module.
(Refer to Restraint - "Driver Airbag (DAB) Module and Clock Spring")
3. Remove the steering wheel.
(Refer to Steering System - "Steering Column and Shaft")
4. Disengage the steering wheel remote control switch assembly. (Refer to Steering System - "Steering Wheel")
5. Loosen the screw and then remote control switch assembly (A) from the steering wheel body.
6. Install in the reverse order of removal.
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Restraint
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident including electric
shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to “High Voltage Shutoff Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents like electric
shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety accidents(Refer to
“Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage components should be
covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power Cable, BMS
ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current Sensor, Safety Plug, Main
Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit (EPCU), High Voltage Heater, High Voltage
Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Illustration
Description
Insulation gloves
Used when inspecting or working on the high voltage components
[Insulation performance : 1000V / 300A or above]
Insulation shoes
Used when inspecting or working on the high voltage components
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Insulation clothes
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high voltage
battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
All removed high voltage components are placed on an insulation mat
to prevent safety accidents.
Insulation sheet is used to cover high voltage components to protect
people not wearing personal protective equipment from safety
accidents.
Used for infomring that it is dangerous to come over this line.
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Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use water or other
types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such a component
must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
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• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to prevent rapid
discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the high voltage
battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high voltage battery SOC
reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and inoperative A/C
compressor, disabling the A/C compressor.
Restraint
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow
the safety instructions may result in serious electrical injuries.
High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power Cable, BMS
ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current Sensor, Safety Plug, Main Fuse,
Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit (EPCU), High Voltage Heater, High Voltage Heater
Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
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(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug has been
removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the high voltage system.
Restraint
General
The supplemental restraint system (SRS) is designed to supplement the seat belt to help reduce the risk or severity of injury to the driver and passenger by
activating and deploying the driver, passenger and side airbags and belt pretensioners in certain frontal or side collisions.
The SRS consists of ; a driver side airbag module located in the center of the steering wheel which contains a folded cushion and an inflator unit ; a
passenger side airbag module located in the passenger side crash pad which contains a folded cushion assembled with an inflator unit ; a side airbag
module located in the front seat which contains folded cushions and inflator units ; and curtain airbag modules located inside headliners which contain
folded cushions and inflator units. The impact sensing function of the SRSCM is carried out by electronic accelerometer that continuously measures the
vehicle’s acceleration and delivers a corresponding signal through amplifying and filtering circuitry to the microprocessor.
SRSCM (SRS Control Module)
SRSCM detects front impact from the front impact sensor and side impact from the side impact sensor and determines the airbag module deployment.
1. DC/DC Converter: DC/DC converter in power supply unit includes up/down transformer converter, and provides ignition voltage to 2 front airbag ignition
circuits and internal operation voltage to the SRSCM. If the internal operation voltage is below critical value setting, it will reset.
2. Back up power supply: SRSCM has a separate back up power supply which will instantly supply deployment energy in low voltage condition or upon
power failure due to front crash.
3. Self diagnosis: SRSCM will constantly monitor current SRS operation status and detect system failure when the vehicle power supply is on. System
failure may be checked by trouble codes using GDS.
4. SRS warning lamp on: Upon detecting error, the module will transmit signal to SRSCM indicator lamp located at cluster. MIL lamp will indicate driver
SRS error. Upon ignition key on, SRS lamp will turn on for about six seconds.
5. Trouble code registration: When an error occurs in the system, SRSCM will save DTC corresponding to the error. DTC can be cleared only by Hi-Scan.
However, if an internal fault code is logged or if a crash is recorded, the fault clearing will not happen.
6. Self diagnostic connector: Data stored in SRSCM memory will be viewed using GDS.
7. Once airbag is deployed, SRSCM should be replaced with new SRSCM.
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Restraint
Tightening Torque
Item
Passenger Airbag (PAB)
Curtain Airbag (CAB)
Nm
kgf.m
lb-ft
7.8 ~ 11.8
0.8 ~ 1.2
5.9 ~ 8.6
Bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.9 ~ 8.6
Nut
3.9 ~ 5.9
0.4 ~ 0.6
2.9 ~ 4.4
Side Airbag (SAB)
5.9 ~ 7.8
0.6 ~ 0.8
4.3 ~ 5.8
SRSCM
7.8 ~ 9.8
0.8 ~ 1.0
5.7 ~ 7.3
Front Impact Sensor (FIS) Mounting nut
7.8 ~ 9.8
0.8 ~ 1.0
5.7 ~ 7.3
Pressure Side Impact Sensor (PSIS) Mounting Screw
3.5 ~ 5.7
0.36 ~ 0.58
2.6 ~ 4.2
Side Impact Sensor (SIS) Mounting Bolt
7.8 ~ 9.8
0.8 ~ 1.0
5.7 ~ 7.3
Restraint
Components
1. Driver Airbag (DAB)
2. Steering Wheel
3. Clock Spring
4. Seat Belt Pretensioner (BPT)
5. Side Impact Sensor (SIS)
6. Side Airbag (SAB)
7. Passenger Airbag (PAB)
Components Location
Supplemental Restraint System Control Module (SRSCM)
8. Front Impact Sensor (FIS)
9. Curtain Airbag (CAB)
10. Supplemental Restraint System Control Module(SRSCM)
11. Airbag Warning Lamp
12. Emergency Fastening Device (EFD)
13. Pressure Side Impact Sensor (PSIS)
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Front Impact Sensor (FIS)
Side Impact Sensor (SIS)
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Driver Airbag (DAB) / Passenger Airbag (PAB)
Side Airbag (SAB)
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Curtain Airbag (CAB)
Seat Belt Pretensioner (BPT) / Emergency Fastening Device (EFD)
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Restraint
Warning Lamp Activation
Warning Lamp Behavior after Ignition On
As soon as the operating voltage is applied to the SRSCM ignition input, the SRSCM activates the warning lamp for a lamp check.
The lamp will turn on for 6 seconds during the initialization phase and will then turn off afterward.
If there are any active faults after the operating voltage is applied, the warning lamp will flicker on for 6 seconds and off for 1 second to alert the driver.
1. Active fault or historical fault counter is greater or equal to 10.
2. Normal or historical fault counter is less than 10.
3. When turning the ignition switch ON during variant coding (EOL) mode, the airbag warning lamp is turned on and blinks at intervals of 1 second till the
coding is completed.
When the variant coding is successfully completed, the airbag warning lamp will turn on for 6 seconds and then turn off. Otherwise, the airbag warning
lamp will continuously flicker at intervals of 1 second.
(1) In case the variant coding is successfully completed
(2) In case the variant coding is not completed
When there is active fault in airbag system or SRSCM internal fault, the variant coding (EOL) cannot be completed. In this case, perform the variant
coding (EOL) procedure again after troubleshooting with the GDS.
SRSCM Independent warning lamp activation
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There are certain fault conditions in which the SRSCM cannot function and thus cannot control the operation of the standard warning lamp. In these cases,
the standard warning lamp is directly activated by appropriate circuitry that operates independently of the SRSCM.
These cases include:
1. Loss of battery sypply to the SRSCM : warning lamp stays on
2. Loss of internal operating voltage : warning lamp stays on
3. Loss of Microprocessor operation : warning lamp stays on
4. SRSCM not connected : warning lamp stays on through the shorting bar
Telltale Lamp Activation
The Telltale Lamp indicates whether the Passenger Airbag (PAB) is enabled or disabled according to the occupant status on passenger seat. If the
passenger seat is empty or occupied with a child (or a child seat), the Passenger Airbag is disabled and the Telltale Lamp is turned ON to inform the driver
that the PAB is disabled. As soon as operating voltage is applied to the SRSCM ignition input, the SRSCM activates telltale lamp to prove out. ODS
(Occupant Detection System) will send an unknown status to the SRSCM as a default setting for passenger airbag deployment during the validation period.
After turning the ignition on, talltale lamp will turn on for 4 seconds and turn off for 3 seconds during the initialization phase and will keep ON afterward until
receiving a valid enabling message from ODS system.
Restraint
Special Service Tools
Tool Name / Number
Illustration
Description
Deployment tool
0957A-34100A
Used for deploying airbag
Deployment adapter
0957A-3F100
Used with the deployment tool (0957A-34100A) to deploy
SAB
Deployment adapter
0957A-3Q100
Used with the deployment tool (0957A-34100A) to deploy
DAB, PAB, CAB, BPT and EFD
Dummy
0957A-38200
A simulator that checks the resistance of each wiring harness
Dummy adapter
0957A-3F000
Used with the dummy (0957A-38200) to check the resistance
of SAB
Dummy adapter
0957A-2G000
Used with the dummy (0957A-38200) to check the resistance
of DAB, PAB, CAB, BPT and EFD
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DAB : Driver Airbag
PAB : Passenger Airbag
SAB : Side Airbag
CAB : Curtain Airbag
BPT : Seat Belt Pretensioner
EFD : Emergency Fastening Device
Restraint
Precautions
General Precautions
Please read the following precautions carefully before performing the airbag system service.
Carefully observe the instructions described in this manual as misuse of airbags may result in accidental deployment of airbags, damage or injuries.
• Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least
three minutes before beginning to work.
The contents in the memory are not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery.
• Use only the replacement parts manufactured to the same standards and quality as the original parts..
Do not reuse SRS parts removed from other vehicles. Use only new parts when repairing the SRS.
• Carefully inspect any SRS parts before installation. Do not install any parts that show signs of being dropped or improperly handled, such as dents,
cracks or deformation.
• Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector.
Airbag Handling and Storage
Do not disassemble the airbags as there are no serviceable parts. Once an airbag has been deployed, it cannot be repaired nor reused.
For temporary storage of the air bag during service, please observe the following precautions:
• Store the removed airbag with the pad surface up.
• Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly.
• Store the removed airbag on secure, flat surface away from any high heat source (exceeding 85 C/185 F).
• Never perform any electrical inspections, such as measuring resistance, to the airbags.
• Do not position yourself in front of the airbag assembly during removal, inspection, or replacement.
• Refer to the scrapping procedures for disposal of the damaged airbag.
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• Be careful not to impact or bump on the SRS unit, the side impact sensors or the front impact sensors whenever the ignition switch is ON. Wait for at
least three minutes after the ignition switch is turned OFF before beginning to work.
• During installation or replacement, be careful not to bump on the area (by impacting with a wrench, hammer, etc.) around the SRS unit, the side impact
sensor and the front impact sensor as any impact on the airbags may accidentally deploy them to cause possible damage or injury.
• Replace the front airbag module, SRSCM and FIS after the front airbag is deployed. Replace the airbag wiring if it is damaged. Replace the side airbag
module, the curtain airbag module, SRSCM and SIS after the side airbag is deployed. Replace the airbag wiring if it is damaged.
• If the airbags or the side airbags were not deployed in a collision, inspect for any damage or deformation on the SRS unit and the side impact sensors. If
any damage is found, replace the SRS unit, the front impact sensor and/or the side impact sensors.
• Do not disassemble the SRS unit, the front impact sensor or the side impact sensors.
• Turn the ignition switch OFF, disconnect the battery negative cable and wait for at least three minutes before beginning to install or replace the SRS
unit.
• Be sure that the SRS unit, the front impact sensor and side impact sensors are installed securely with mounting bolts.
• Be careful not to spill water or oil on the SRS unit, the front impact sensor or the side impact sensors and keep them away from dust.
• Store the SRS unit, the front impact sensor and the side impact sensors in a cool (15 ~ 25 C/ 59 ~ 77 F) and dry (30 ~ 80% relative humidity, no
moisture) area.
Wiring Precautions
SRS wiring can be identified by special yellow outer covering. Observe the instructions described in this section.
• Never attempt to modify, splice or repair SRS wiring. If there is an opening or damage on SRS wiring, replace the harness.
• Be sure to install the harness wires so that they are not pinched, or interfering with other parts.
• Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause
intermittent problems that are difficult to diagnose.
Precautions for Electrical Inspections
• When using electrical test equipment, insert the probe of the tester into the wire side of the connector.
Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector.
• Use a u-shaped probe. Do not force the probe into a connector.
• Use specified service connectors for troubleshooting.
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Using improper tools could cause an error in inspection due to poor metal contact.
Spring-loaded Lock Connector
Some SRS system connectors come with spring-loaded locks.
Airbag Connector
Disconnecting
To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector.
Pull the connector halves apart. Be sure to pull on the sleeve instead of the connector half.
Connecting
Hold both connector halves and press firmly until the projection(C) of the sleeve-side connector clicks to lock.
Restraint
Component Replacement after Deployment
Before doing any SRS repairs, use the GDS to check for DTCs. Refer to the Diagnostic Trouble Code list for repairing of the related DTCs.
When the front airbag(s) deployed after a collision, replace the following items.
- SRSCM
- Deployed airbag(s)
- Seat belt pretensioner(s)
- Emergency fastening device
- Front impact sensors
- SRS wiring harnesses
- Inspect the clock spring for heat damage.
If any damage is found, replace the clock spring.
When the side/curtain airbag(s) deployed after a collision, replace the following items.
- SRSCM
- Deployed airbag(s)
- Side impact sensor(s) on the deployed side(s)
- SRS wiring harnesses
When the vehicle is completely repaired, verify that the SRS airbag system is OK.
- When the ignition switch is turned ON, the SRS indicator should come on for about 6 seconds before going off.
Restraint
Description
Driver Airbag (DAB) is installed inside the steering wheel and is electrically connected to SRSCM with a clock spring. It protects the driver from impact by
deploying a bag when frontal crash occurs. The SRSCM determines the deployment of Driver Airbag (DAB).
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Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified tester. When the circuit resistance is
measured with a tester, accidental deployment of airbag may result in serious personal injury.
Restraint
Components
1. Driver Airbag (DAB)
2. Steering Wheel
3. Clock Spring
Restraint
Removal
1. Set the front tires facing straight ahead before removing the steering wheel.
If any of the steering wheel or the front tires are not set straight ahead together, it may affect the number of circulation of steering wheel and may
damage the cable inside the clock spring.
2. Disconnect the battery negative cable.
After disconnecting the battery negative cable, wait for at least thirty seconds.
3. Release the connector locking pin, and then disconnect the driver airbag module connector (B).
The removed airbag module should be stored in a clean, dry place with the pad cover facing up.
4. Remove the steering wheel.
(Refer to Steering System - "Steering Column and Shaft")
5. Loosen the screws and then remove the steering wheel column shroud (A).
6. Disconnect the clock spring and horn connector (A) and then remove the clock spring.
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Inspection
Driver Airbag (DAB)
If any improper parts are found during the following inspection, replace the airbag module with a new one.
Never attempt to measure the circuit resistance of the airbag module (squib) even with a specified tester as measuring circuit resistance with a tester
may result in accidental airbag deployment that leads to serious personal injury.
1.
2.
3.
4.
Check pad cover for dents, cracks or deformities.
Check the airbag module for dents, cracks or deformities.
Check hooks and connectors for damage, terminals for deformities, and harness for binds.
Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel.
Clock Spring
1. With even one abnormality discovered from the following check ups, the clock spring should be replaced with a new one.
2. Check connectors and protective tube for damage, and terminals for deformities.
Installation
1. Set the front tires straight-ahead before assembling the steering wheel.
If any of the steering wheel or the front tires are not set straight ahead together, it may affect the number of circulation of steering wheel and may
damage the cable inside the clock spring.
2. Disconnect the battery negative cable.
After disconnecting the battery negative cable, wait for at least thirty seconds.
3. Set the clock spring in the center before assembling it to the steering wheel.
(1) Turn the clock spring clockwise to the stop.
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(2) Make 3 revolutions counterclockwise and make sure to set an array on the mark (▶◀).
(In case of 18ch heating wire, make 2 revolutions counterclockwise).
(Once the array is set on the mark (▶◀), the clock spring is automatically locked.)
4.
5.
6.
7.
8.
Connect the clock spring harness connector and horn harness connector to the clock spring.
Install the steering wheel column cover and the steering wheel. (Refer to the Steering System group- Steering Column and Shaft)
Connect the Driver Airbag (DAB) module connector, and then install the Driver Airbag (DAB) module on the steering wheel.
Connect the battery negative cable.
After installing the airbag, confirm proper system operation:
- Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds before going off.
- Make sure that the horn is working.
Restraint
Description
Passenger Airbag (PAB) module is located in the passenger crash pad. The PAB contains 2 firing squibs of airbag and 1 firing squib of active vent. The
deployment timing of both 2 firing squibs of airbag and 1 firing squib of active vent depends on the crash speed or the level of tightening of the seat belt. At
the moment of collision, the firing squib of active vent inflates the airbag, and when the passenger collides with the airbag, the gas inside escapes through a
small vent hole. This operation will reduce the level of injury to the passenger's head.
At first, the active vent instantly deploys the airbag by inflating it at a high pressure, and after the deployment, it slowly discharges the gas from the upper
airbag.The Working Principle of Tether Cutter: On receiving an electrical signal, the Tether Cutter cuts off a strap from the active vent to open a hole in the
upper airbag.
The working range of Active Vent
1. If occupant in passenger seat is not belted, active vent is disposed in the end of crash event regardless of crash severity.
2. If occupant is belted and crash is severe enough to require 2 stage passenger airbag deployment, active vent is activated to optimize occupant
protection.
3. Low-Speed + Belted : Inflator of Primary Fire + 2 Stage & Active Vent disposal in the end of crash event.
Never attempt to measure the circuit resistance of the airbag module (squib) even with a specified tester as measuring circuit resistance with a tester
may result in accidental airbag deployment that leads to serious personal injury.
Restraint
Components
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Restraint
Removal
1. Disconnect the battery negative cable and wait for at least thirty seconds before beginning to work.
2. Remove the glove box housing.
(Refer to Body - "Glove box housing")
3. Remove the passenger airbag mounting bolts (A).
4. Disconnect the passenger airbag connector (B).
5. Remove the crash pad.
(Refer to Body - "Main crash pad assembly")
Replace any crash pads damaged while deploying the PAB.
6. Remove the mounting bolts from the crash pad and then remove the passenger airbag (A).
The removed airbag module should be stored in a clean, dry place with the airbag cushion up.
Installation
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable from the battery and wait for at least thirty seconds before beginning to work.
before beginning work.
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3. Place a passenger airbag on the crash pad and tighten the passenger airbag (A) mounting bolts.
4. Install the crash pad.
(Refer to Body - "Main crash pad assembly")
5. Connect the passenger airbag connector (B).
6. Tighten the passenger airbag mounting bolts (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
7. Reinstall the glove box housing.
(Refer to Body - "Glove box housing")
8. Reconnect the battery negative cable.
9. After installing the passenger airbag (PAB), confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint
Description
The Side Airbags (SAB) are installed inside the front seat to protect the driver and front passenger from danger when side crash occurs. The SRSCM
determines deployment of side airbag by using Side Impact Sensor (SIS) signal.
Never attempt to measure the circuit resistance of the airbag module (squib) even with a specified tester as measuring circuit resistance with a tester
may result in accidental airbag deployment that leads to serious personal injury.
Restraint
Components
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Restraint
Removal
The side airbag cannot be disassembled from the seat back assembly, so replace assembly when replacing the side airbag.
1. Disconnect the battery negative cable, and wait for at least thirty seconds before beginning to work.
2. Remove the front passenger seat assembly.
(Refer to Body - "Front seat")
3. Remove the front seat shield inner cover.
(Refer to Body - "Front seat shield inner cover")
4. Remove the front seat shield outer cover.
(Refer to Body - "Front seat shield outer cover")
5. After loosening the mounting bolts, disconnect the front seat back assembly (A) and front seat cushion assembly (B).
Tightening torque :
44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)
Installation
When installing the harness wires, be sure that they are not pinched or interfering with other parts.
• Do not open the lid of the side airbag cover.
• Make sure that the airbag assembly cover is installed properly. Improper installation may hinder proper deployment.
1.
2.
3.
4.
5.
6.
Remove the ignition key from the vehicle.
Disconnect the battery negative cable and wait for at least thirty seconds.
Install in the reverse order of removal.
Fully recline and slide the front seat forward, and make sure that the harness wires are not pinched or interfering with other parts.
Reconnect the battery negative cable.
After installing the side airbag (SAB), confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint
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Description
Curtain airbags are installed inside the headliner (LH and RH) to protect the driver and passenger from danger when side crash occurs. The SRSCM
determines deployment of curtain airbag by using side impact sensor (SIS) signal.
Never attempt to measure the circuit resistance of the airbag module even with a specified tester as measuring circuit resistance with a tester may
result in accidental airbag deployment that leads to serious personal injury.
Restraint
Components
Restraint
Removal
1. Disconnect the battery negative cable and wait for at least thirty seconds before beginning to work.
2. Remove the roof trim assembly.
(Refer to Body - "Roof trim assembly")
3. Disconnect the curtain airbag harness connector (A).
4. After loosening the mounting bolts and nuts remove the curtain airbag.
Installation
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable and wait for at least thirty seconds.
3. Tighten the curtain airbag mounting bolts and nuts.
Tightening torque
Bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Nut : 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
• Never twist the airbag module during installation as twisted module may result in abnormal operation. (of the airbag module.)
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4. Connect the curtain airbag connector.
5. Install the roof trim assembly.
(Refer to Body - "Roof trim assembly")
6. Reconnect the battery negative cable.
7. After installing the curtain airbag (CAB), confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint
Airbag Disposal
Special tool required
Deployment tool 0957A-34100A
Before scrapping any airbags or side airbags (including those in a whole vehicle to be scrapped), the airbags or side airbags must be deployed. If the
vehicle is still within the warranty period, before deploying the airbags or side airbags, the Technical Manager must give approval and/or special instruction.
Only after the airbags or side airbags have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags or side
airbags appear intact (not deployed), treat them with extreme caution. Follow this procedure.
Deploying airbags in the vehicle
If an SRS equipped vehicle is to be entirely scrapped, its airbags or side airbags should be deployed while still in the vehicle. The airbags or side airbags
should not be considered as salvageable parts and should never be installed to other vehicles.
1. Turn the ignition switch OFF, disconnect the battery negative cable and wait for at least three minutes.
2. Confirm that each airbag or side airbag is securely mounted.
3. Confirm that the special tool is functioning properly by following the check up procedure.
(1) Driver’s Airbag :
A. Remove the driver’s airbag and install the SST (0957A-3Q100).
B. Install the driver’s airbag on the steering wheel.
(2) Front Passenger’s Airbag :
A. Remove the glove box, and then disconnect the 2P connector between the front passenger’s airbag and SRS main harness.
B. Install the SST(0957A-3Q100).
(3) Side Airbag :
A. Disconnect the 2P connector between the side airbag and side wire harness.
B. Install the SST (0957A-3F100).
(4) Curtain Airbag :
A. Disconnect the 2P connector between the curtain airbag and wire harness.
B. Install the SST (0957A-3Q100).
(5) Seat Belt Pretensioner :
A. Disconnect the 2P connector from the seat belt pretensioner.
B. Install the SST (0957A-3Q100).
(6) Emergency Fastening Device :
A. Disconnect the 2P connector from the emergency fastening device.
B. Install the SST (0957A-3Q100).
4. Place the deployment tool at least thirty feet (10meters) away from the airbag.
5. Connect a 12 volt battery to the tool.
6. Push on the tool's deployment switch to deploy the airbag (Deployment is both highly audible and visible: It is characterized by a loud noise and rapid
inflation of the bag, followed by slow deflation).
7. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag and seal it securely.
Deploying the airbag out of the vehicle
If an intact airbag has been removed from a scrapped vehicle, or has been found defective or damage during transit, storage or service, it should be
deployed as follows:
1. Confirm that the special tool is functioning properly by following the check up procedure.
2. Position the airbag face up, outdoors on flat ground at least thirty feet (10meters) from any obstacles or people.
Disposal Of Damaged Airbag
1. When disposing damaged airbag already installed in a vehicle, follow the removal procedure of driver's, front passenger's and side airbags.
2. In all cases, make a short circuit by twisting the two airbag inflator wires together.
3. Pack the airbag in exactly the same package that the new replacement part comes in.
Restraint
Description
The Seat Belt Pretensioners (BPT) are installed inside Center Pillar (LH & RH). When a vehicle crashes with a certain degree of frontal impact, the
pretensioner seat belt helps to reduce the severity of injury to the front seat occupants by retracting the seat belt webbing. This prevents the front occupants
from thrusting forward and hitting the steering wheel or the instrument panel when the vehicle crashes.
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Never attempt to measure the circuit resistance of the Seat Belt Pretensioner (BPT) even with a specified tester as measuring circuit resistance with a
tester may result in accidental ignition of the pretensioner that leads to serious personal injury.
Restraint
Components
Restraint
Removal
1. Disconnect the battery negative cable, and wait for at least thirty seconds before beginning to work.
2. To remove the emergency fastening device (C), keep on pushing the lock pin (A) as arrow direction. And then remove the seat belt after pushing the lock
pin (B).
3. Remove the center pillar lower trim.
(Refer to Body - "Center pillar trim")
4. Remove the center pillar upper trim.
(Refer to Body - "Center pillar trim")
5. After loosening the mounting bolt, remove the front seat belt upper anchor (A).
6. Disconnect the seat belt pretensioner connector (A).
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7. Loosen the seat belt pretensioner mounting bolt (B) and remove the seat belt pretensioner.
Installation
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable and wait for at least thirty seconds.
3. Install the seat belt pretensioner with bolt (B).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
4. Connect the seat belt pretensioner connector (A).
5. Install the front seat belt upper anchor (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
6. Install the center pillar upper trim.
(Refer to Body - "Center pillar trim")
7. Install the center pillar lower trim.
(Refer to Body - "Center pillar trim")
8. Insert the seat belt to the emergency fastening device (A).
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Make sure that the lock pin is connected properly.
9. Reconnect the battery negative cable.
10. After installing the seat belt pretensioner, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint
Description
Emergency Fastening Device (EFD) is deployed concurrently with the Belt Pretensioner to strongly pull down the seat belt during a deployment condition
after a collision. It is located near the anchor on driver and passenger seats to make up for the existing short stroke. EFD is an auxiliary equipment that
gives extra protection to the driver and passenger from breaking away and leaning toward the anchor side during a collision by preventing the seat belts
from getting loose.
Never measure resistance of EFD directly as the electric current from measuring device may cause unexpected deployment of airbag.
Restraint
Components
Restraint
Removal
1. Disconnect the battery negative cable, and wait for at least thirty seconds before beginning to work.
2. To remove the emergency fastening device (C), keep on pushing the lock pin (A) in the direction of arrow. And then remove the seat belt after pushing
the lock pin (B).
3. Remove the center pillar lower trim.
(Refer to Body - "Center pillar trim")
4. Disconnect the emergency fastening device connector (A).
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5. Loosen the mounting bolt (B) and then remove the emergency fastening device.
Installation
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable and wait for at least thirty seconds.
3. Install the emergency fastening device with bolt (B).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
4. Connect the emergency fastening device connector (A).
5. Install the center pillar lower trim.
(Refer to Body - "Center pillar trim")
6. Insert the seat belt to the emergency fastening device (A).
Make sure that the lock pin is connected properly.
7. Reconnect the battery negative cable.
8. After installing the emergency fastening device, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint
Description
The primary purpose of the SRSCM (Supplemental Restraints System Control Module) is to determine an event that warrants restraint system air bag
deployment. The SRSCM must decide whether to deploy the restraint system or not. After determining that pretensioners and/or airbag deployment is
required, the SRSCM must supply sufficient power to the pretensioners and airbag igniters to initiate deployment.
The SRSCM determines whether or not an impact requires deployment of pretensioners and/or airbags based on data obtained from impact sensors and
other components in conjunction with safety function.
The SRSCM will not be ready to detect a crash event or to activate the restraint system devices until the signals in the SRSCM circuitry are stabilized.
While it is possible that the SRSCM can activate the safety restraint devices, it is guaranteed to fully function after completing validation.
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The SRSCM must perform a diagnostic routine and light a system readiness indicator at key-on. The system must perform a continuous diagnostic routine
and provide fault annunciation through a warning lamp indicator in the event of fault detection. A serial diagnostic communication interface will be used to
facilitate servicing of the restraint control system.
The yaw and G sensors which are used in ESC are located inside the SRSCM. The sensor signal is sent by a separate CAN signal between the ESC
control module and SRSCM.
Restraint
Components
Restraint
Removal
1.
2.
3.
4.
Remove the ignition key from the vehicle.
Disconnect the battery negative cable and wait for at least three minutes before beginning to work.
Disconnect the DAB, PAB, SAB, CAB and BPT connectors.
Remove the floor console.
(Refer to Body - "Floor console")
5. Remove the rear heating joint duct (A).
6. Pull up the lock of the SRSCM connector and disconnect the connector (A).
7. Remove the SRSCM mounting bolts (3EA) from the SRSCM, and then remove the SRSCM.
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Installation
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable and wait for at least three minutes before beginning to work.
3. Install the SRSCM with the SRSCM mounting bolts.
Tightening torque (SRSCM Mounting Bolt) :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.7 ~ 7.3 lb-ft)
• Use new mounting bolts when replacing the SRSCM after a collision.
• When installing the airbag wiring harness, ground points(C) must be installed.
4. Connect the SRSCM harness connector.
5. Install the rear heating joint duct.
6. Install the floor console.
(Refer to Body - "Floor console")
7. Reconnect the battery negative cable.
8. After installing the SRSCM, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
SRSCM senses vehicle rollovers. SAB, CAB, BPT may deploy if a technician moves the SRSCM from the vehicle in IGN ON state. For this reason,
turn the IGN OFF before safely removing the SRSCM from the vehicle.
Variant coding
After replacing the SRSCM with a new one, one MUST perform the "Variant Coding" procedure.
1. In SRSCM variant coding mode, the airbag warning lamp periodically flickers (ON: 0.5sec., OFF: 0.5sec.) until the coding is normally completed.
2. If the variant coding has failed, DTC B1762 (ACU Coding Error) will be displayed and the warning lamp will be turned on.
In this case, perform the variant coding procedure again after confirming the cause in “DTC Fault State Information”.
Variant Coding can be performed up to 255 times, but if the number of coding work exceeds 255 times, DTC B1683 (Exceed Maximum coding
Number) will be displayed and SRSCM must be replaced.
3. If the battery voltage is low (less than 9V) when attempting the Variant Coding, DTC B1762 will be displayed instead. In this case, charge the
battery as the first thing and then proceed with the variant coding procedure.
This is because although Variant Coding is normally performed, DTC B1762 and low battery will be displayed.
Variant coding Procedure
■ On-Line type on GDS
1.
2.
3.
4.
Ignition "OFF", connect scan tool.
Ignition "ON" & Engine "OFF" select vehicle name and airbag system.
Select Variant coding mode.
Follow steps as in screen shots below.
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1) Initial ACU Variant Coding screen
2) VIN Code entering screen
3) Variant coding's proceeding screen-1
4) Variant coding's proceeding screen-2
5) Variant coding is completed
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1)Text display for Incomplete ACU Coding after finiching variant coding
2) Screen of communication failure
■ Off-line type on GDS (This can be used when not connected to the internet)
1) Initial ACU Variant Coding screen
2) ACU CODING Code entering screen
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3) echecking previously entered ACU CODING code
4) Variant coding's proceeding screen-1
5) Variant coding's proceeding screen-2
6) Variant coding is completed
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1) Screen of incomplete ACU coding after finishing variant coding
Restraint
Description
The Front Impact Sensors (FIS) are installed in the Front End Module (FEM). These remote sensors are used to detect acceleration due to a collision at the
mounting location.
The primary purpose of the Front Impact Sensor (FIS) is to provide an indication of a collision. The Front Impact Sensor (FIS) sends acceleration data to the
SRSCM.
Restraint
Components
Restraint
Removal
• Removal of the airbag must be performed according to the precautions / procedures described previously.
• Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s).
• Do not turn the ignition switch ON nor connect the battery cable while replacing the front impact sensor.
1. Disconnect the battery negative cable and wait for at least thirty seconds before beginning to work.
2. Disconnect the front impact sensor connector (A).
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3. Loosen the mounting bolt and then remove the front impact sensor (B) and extension harness.
Installation
• Do not turn the ignition switch ON nor connect the battery cable while replacing the front impact sensor.
1. Install the new front impact sensor.
2. Tighten the front impact sensor (B) mounting bolt.
Tightening torque :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.7 ~ 7.3 lb-ft)
3. Connect the front impact sensor connector (A).
4. Reconnect the battery negative cable.
5. After installing the Front Impact Sensor, confirm proper system operation:
A. Turn the ignition switch ON the SRS indicator light should be turned on for about six seconds and then go off.
Restraint
Description
Side Impact Sensor (SIS) system consists of two P-SIS, installed at each center of front door modules (LH and RH), and two SIS, installed at each center of
nearby pillars (LH and RH).
P-SIS or Pressure Side Impact Sensor detects pressure due to collision at its mounting location..
Side Impact Sensor is also called A-SIS as it detects acceleration.
SRSCM determines the deployment of airbag and the time of deployment based on the collision signal from the SIS at the time of collision.
Restraint
Components
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Restraint
Removal
Pressure Side Impact Sensor
• Removal of the airbag must be performed according to the precautions / procedures described previously.
• Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s).
• Do not turn the ignition switch ON nor connect the battery cable while replacing the front impact sensor.
1. Disconnect the battery negative cable and wait for at least thirty seconds before beginning to work.
2. Remove the front door trim.
(Refer to Body - "Front door trim")
3. Disconnect the pressure side impact sensor connector (A) and remove the pressure side impact sensor mounting screws (B).
Side Impact Sensor
1. Disconnect the battery negative cable and wait for at least three minutes before beginning to work.
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2. To remove the emergency fastening device (C), keep pressing on the lock pin (A) in the direction of the arrow, and then remove the seat belt after
pushing the lock pin (B).
3. Remove the center pillar lower trim.
(Refer to Body - "Center pillar trim")
4. Disconnect the side impact sensor connector (A).
5. Loosen the side impact sensor mounting bolt and then remove the side impact sensor (B).
Installation
Pressure Side Impact Sensor
1. Install the new pressure side impact sensor with the screws (B) and then connect the pressure side impact sensor connector (A).
Tightening torque :
3.5 ~ 5.7 N.m (0.4 ~ 0.6 kgf.m, 2.6 ~ 4.2 lb-ft)
• Use specified screws.
2. Install the front door trim.
(Refer to Body - "Front door trim")
3. Reconnect the battery negative cable.
4. After installing the pressure side impact sensor, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
• Comply with the specified tightening torque in order to prevent Pressure - Side Impact Sensors (P-SIS) from damages and screw prommet from
missing.
• Problems may arise in the durability of P-SIS or impact sensing performance may decrease if screw grommet is missing.
• The door module must not be transformed because the SRSCM defines an impact through the pressure sensor in the door module.
Side Impact Sensor
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• Do not turn the ignition switch ON nor connect the battery cable while replacing the front impact sensor.
1. Install the new side impact sensor (B) with the bolt then connect the side impact sensor connector (A).
Tightening torque:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.7 ~ 7.3 lb-ft)
2. Install the center pillar lower trim.
(Refer to Body - "Center pillar trim")
3. Insert the seat belt to the emergency fastening device (A).
Make sure that the lock pin is connected properly.
4. Reconnect the battery negative cable.
5. After installing the Side Impact Sensor, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
Restraint
Description
The SRSCM shall monitor the status of the driver and front passenger seat belt buckle. The SRSCM provides one pin each for the driver and front
passenger seat belt buckle status input. The seat belt buckle circuit operates from internal boost voltage supplied by the SRSCM, and uses chassis ground
for the signal return. The buckle status shall modify the SRSCM deployment. If the buckle status is unbuckled, the corresponding pretensioner will not be
deactivated.
Restraint
Components
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Restraint
Removal
1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work.
2. Remove the front seat assembly.
(Refer to Body - "Front seat")
3. Remove the seat belt buckle switch.
(Refer to Body - "Front seat belt buckle")
Installation
Be sure to install the harness wires so they will not pinch or interfere with other parts.
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable, and wait for at least three minutes before beginning work.
3. Install the seat belt buckle switch.
(Refer to Body - "Front seat belt buckle")
4. Install the front seat assembly.
(Refer to Body - "Front seat")
5. Reconnect the battery negative cable.
6. After installing the seat belt buckle switch, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator should be turned on for about six seconds and then go off.
Restraint
Description
In order to make normal activation of airbag system, SRSCM detects DTC(s) for the Passenger side Body Detection System. If the seat is occupied, Body
sensor detects how measuring electrostatic capacity and send signal to SRSCM via CAN. SRSCM recognizes the signal as 2(two) different classifications;
that is, class #1 (Empty or child seat), class #2 (Small, Large).With these signal, ACU determines whether it needs to deploy PAB(Passenger Airbag) or not.
If you strike or spin the SRSCM with the IG “ON”, the seat-belt pretensioner, curtain-airbag or side-airbag could be deployed. Handle it with care.
Restraint
Components
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Restraint
Removal
1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work.
2. Remove the front passenger seat assembly. (Refer to the Body group- Seat)
3. Remove the seat cushion assembly. (Refer to the Body group- Seat)
Installation
1. Install the ODS equipped seat cushion assembly. (Refer to the Body group- Seat)
2. Install the front passenger seat assembly.
(Refer to the Body group - seat)
3. Reconnect the battery negative cable.
4. After installing the ODS, confirm proper system operation :
A. Turn the ignition switch ON the SRS indicator should be turned on for about six seconds and then go off.
B. Telltale lamp will turn on for 4 seconds and be turned off for 3 seconds. After the 7 seconds, it shall remain off if the ODS does not require
suppression and the passenger airbag is enabled.
Restraint
Circuit Diagram (1)
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Circuit Diagram (2)
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Circuit Diagram (3)
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SRSCM Connector Terminal
Harness Connector
Pin No.
1
-
2
3
-
4
5
6
Pin No.
1
-
-
2
3
-
-
-
-
4
G
A/C Control Module (SBR PASS)
5
B
-
6
Passenger Side Impact
Sensor (High)
Passenger Side Impact
Sensor (Low)
-
Function (Connector A)
-
Y
Function (Connector B)
-
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7
P
Smart Junction Box(Fuse - AIR BAG)
7
O
Driver Side Impact Sensor (Low)
8
R
Driver Front Impact Sensor (High)
8
G
Driver Side Impact Sensor (High)
9
L
Driver Front Impact Sensor (Low)
9
-
-
10
11
G
O
Passenger Front Impact Sensor (Low)
Passenger Front Impact Sensor (High)
10
11
B
-
Ground (GF07)
-
12
-
-
12
Gr
Driver Side Air Bag (High)
13
-
-
13
W/B
Driver Side Air Bag (Low)
14
-
-
14
P/B
Passenger Side Air Bag (Low)
15
-
-
15
O/B
Passenger Side Air Bag (High)
16
-
-
16
-
-
17
-
-
17
-
-
18
-
-
18
-
-
19
-
-
19
-
-
20
-
-
20
-
-
21
-
22
21
22
-
R
L
Passenger Pressure Side
Impact Sensor (Low)
Passenger Pressure Side
Passenger Pressure Side
23
24
-
-
23
24
B
R
Driver Curtain Air Bag (High)
Driver Curtain Air Bag (Low)
25
26
Gr
Y
Passenger Air Bag #3 (Low)
Passenger Air Bag #3 (High)
25
26
Y
W
Passenger Curtain Aig Bag (Low)
Passenger Curtain Aig Bag (High)
27
28
-
-
27
28
-
-
29
30
-
-
29
30
-
-
-
31
G
Passenger Seat Balt
Buckle Switch (+)
Br
Integrated Brake Actuation Unit
(Local CAN Low)
32
B/O
Driver Seat Belt Buckle Switch (+)
G
33
B
Driver Seat Belt Buckle Switch (-)-
31
32
-
34
O
Integrated Brake Actuation Unit
(Local CAN High)
Crash Output
34
L
Driver Anchor Pretensioner (High)
35
36
G
O
Driver Air Bag (2nd Satge (Low))
Driver Air Bag (2nd Satge (High))
35
36
Br
Y
Driver Anchor Pretensioner (Low)
Passenger Anchor Pretensioner(Low)
37
38
W
G
Passenger Air Bag #2 (High)
Passenger Air Bag #2 (Low)
37
38
GrB
Passenger Anchor Pretensioner(High)
Driver Seat Belt Pretensioner (High)
39
40
L
Br/O
Driver Air Bag (1st Satge (Low))
Driver Air Bag (1st Satge (High))
39
40
R
Br
Driver Seat Belt Pretensioner (Low)
Passenger Seat Belt Pretensioner (Low)
41
42
Y
Gr
Passenger Air Bag #1 (High)v
Passenger Air Bag #1 (Low)
41
42
L
B
Passenger Seat Belt Pretensioner(High)
Passenger Seat BaltBuckle Switch (-)
43
44
Br
W
C-CAN (Low)
C-CAN (High)
43
44
W
Br
Driver Pressure Side Impact Sensor (Low)
Driver Pressure Side Impact Sensor (High)
33
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Brake System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident including electric
shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to “High Voltage Shutoff Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents like electric
shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety accidents(Refer to
“Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage components should be
covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power Cable, BMS
ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current Sensor, Safety Plug, Main Fuse,
Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit (EPCU), High Voltage Heater, High Voltage Heater
Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Illustration
Description
Insulation gloves
Used when inspecting or working on the high voltage components
[Insulation performance : 1000V / 300A or above]
Insulation shoes
Used when inspecting or working on the high voltage components
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Insulation clothes
Insulation helmet
Safety glasses
Used in the following cases :
• When removing & installing or inspecting the high voltage battery
terminals or wiring where spark may happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
All removed high voltage components are placed on an insulation mat
to prevent safety accidents.
Insulation sheet is used to cover high voltage components to protect
people not wearing personal protective equipment from safety
accidents.
Used for infomring that it is dangerous to come over this line.
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Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use water or other
types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such a component
must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
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• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to prevent rapid
discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the high voltage
battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high voltage battery SOC
reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and inoperative A/C
compressor, disabling the A/C compressor.
Brake System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the
safety instructions may result in serious electrical injuries.
High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power Cable, BMS ECU,
Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current Sensor, Safety Plug, Main Fuse, Battery
Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
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Remove the safety plug in the follwing order.
5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug has been
removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the high voltage system.
Brake System
Specifications
Item
Front disc brake
Rear disc brake
Type
Specification
Ventilated disc
Disc O.D.
Ø 300 mm (11.81 in)
Disc thickness
28.5 mm (1.10 in)
Caliper piston
Single
Cylinder I.D.
Ø 60.6 mm (2.36 in)
Type
Solid disc
Disc O.D.
Ø 284 mm (11.18 in)
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Parking brake
Disc thickness
10 mm (0.39 in)
Caliper piston
Single
Cylinder I.D.
Ø 38 mm (1.34 in)
Type
EPB
O.D. : Outer Diameter
I.D. : Inner Diameter
Specification (ESC)
Part
Item
Integrated
Brake
Actuation
Unit(IBAU)
Standard value
System
4 Channel 4 Sensor (Solenoid)
Type
Motor, valve relay integrated type
Operating Voltage
10 ~ 16 V
Operating Temperature
-40 ~ 120 °C (-40 ~ 248°F)
Supply voltage
DC 4.5 ~ 20 V
Output current low
5.9 ~ 8.4 mA
Output current high
11.8~ 16.8 mA
Active Wheel speed sensor Output range
Front: 48 teeth, Rear: 47 teeth
Air gap
Pressure
Source
Unit
(PSU)
Total control
(ABS, EBD, TCS,
ESC)
1 ~ 2500 Hz
Tone wheel
Yaw rate& Lateral G
sensor
(CAN TYPE)
Remark
Front
0.4 ~ 1.5 mm
Rear
0.4 ~ 1.0 mm
Operating Voltage
8 ~ 18 V
Current Consumption
Max. 140 mA
Yaw rate sensor measurement range
±120 °/sec
Lateral G sensor measurement range
±1.8g
System
4 Channel 4 Sensor (Solenoid)
Operating Voltage
10 ~ 16 V
Operating Temperature
-40 ~ 125 °C (-40 ~ 248°F)
Motor Power
170 W
Service Standard
Items
Standard value
Brake pedal full stroke
130 mm
Stop lamp switch clearance
1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
Brake pedal free play
1.0 ~ 2.0mm (0.04 ~ 0.08 in)
Front brake disc thickness
28 mm (1.10 in)
Front brake disc pad thickness
11 mm (0.43 in)
Rear brake disc thickness
10 mm (0.39 in)
Rear brake disc pad thickness
10 mm (0.39 in)
Tightening Torque
Items
Hub nut
N.m
kgf.m
lb-ft
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Air bleed screw
6.9 ~ 12.7
0.7 ~ 1.3
5.1 ~ 9.4
Brake tube flare nuts
12.7 ~ 16.7
1.3 ~ 1.7
9.4 ~ 12.3
Front caliper guide rod bolts
21.6 ~ 31.4
2.2 ~ 3.2
15.9 ~ 23.1
Rear caliper guide rod bolts
21.6 ~ 31.4
2.2 ~ 3.2
15.9 ~ 23.1
Front caliper assembly to knuckle
78.5 ~ 98.1
8.0 ~ 10.0
57.9 ~ 72.3
Rear caliper assembly to knuckle
63.7 ~ 73.5
6.5 ~ 7.5
47.0 ~ 54.2
Brake hose to caliper
24.5 ~ 29.4
2.5 ~ 3.0
18.1 ~ 21.7
Brake pedal member bracket bolts
16.7 ~ 25.5
1.7 ~ 2.6
12.3 ~ 18.8
Brake pedal shaft nut
24.5 ~ 34.3
2.5 ~ 3.5
18.1 ~ 25.3
Wheel speed sensor mounting bolt
6.9 ~ 10.8
0.7 ~ 1.1
5.1 ~ 8.0
IBAU bracket mounting bolts
10.8 ~ 12.7
1.1 ~ 1.3
8.0 ~ 9.4
Yaw rate&G sensor mounting nuts
6.9 ~ 10.8
0.7 ~ 1.1
5.1 ~ 8.0
IBAU brake tube flare nuts
13.7 ~ 16.7
1.4 ~ 1.7
10.1 ~ 12.3
PSU bracket mounting bolts
19.6 ~ 29.4
2.0 ~ 3.0
14.5 ~ 21.7
Lubricants
Items
Brake fluid
Brake pedal bushing and bolt
Parking brake shoe and backing plate contacting surface
Recommended
Quantity
DOT 3 or DOT 4
As required
Chassis grease
As required
Heat resistance grease
As required
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Front Caliper guide rod and boot
BG-1(MS511-60)
0.35g ~ 0.8g
Rear Caliper guide rod and boot
BG-1(MS511-60)
0.35g ~0.8g
Brake System
Special Service Tools
Tool(Number and Name)
Illustration
Use
09581-11000
Piston expander
Used to spread the front and rear disc brake
pistons.
09580-3D100
Air bleeding tool
Used to bleed air in brake system.
0k585-E8100
Air bleeding tool
Used to bleed air in brake system.
09580 - 0U000
Rear brake piston
adjuster
Used to spread the rear disc brake piston.
Personal Protective Equipment
Name
Insulation glove
Illustration
Description
Used when inspecting or working on the high voltage components
[Insulation performance : 1000V / 300A or above]
Insulation shoes
Insulation clothes
Insulation helmet
Used when inspecting or working on the high voltage components
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Safety glasses
Used in the case below
• During Removal & installation or inspection of the high voltage
battery terminals or wiring, which spark might happen.
• During working on the high voltage battery pack assembly.
Face shield
Insulation mat
Putting the removed high voltage components on the insulation mat to
prevent safety accidents.
Insulation sheet
Covering the high voltage components with insulation sheet to protect
people not wearing the personal protective equipment from safety
accidents.
Brake System
Troubleshooting
Symptom
Possible Cause
1. Integrated Brake Actuation Unit (Air in system)
Lower pedal or spongy pedal
2. AHB system (Fluid leaks)
Replace
3. Piston seals in IBAU (Worn or damaged)
Replace
1. Brake pedal free play (Minimum)
Brake drag
Brake pull
Replace
3. Piston (Stuck)
Replace
4. Piston (Frozen)
Replace
5. Anchor or Return spring (Inoperative)
Replace
6. Master cylinder (Inoperative)
Replace
7. IBAU (Inoperative)
Replace
1. Piston (Stuck)
Replace
2. Pad or lining (Oily)
Replace
3. Piston (Frozen)
Replace
4. Disc (Scored)
Replace
5. Pad or lining (Cracked or distorted)
Replace
2. Brake system (Air in)
Replace
4. Pad or lining (Cracked or distorted)
Replace
5. Rear brake shoe clearance(Out of adjustment)
Adjust
6. Pad or lining (Oily)
Replace
7. Pad or lining (Glazed)
Replace
8. Disc (Scored)
Replace
9. IBAU (Inoperative)
Replace
10. PSU (Inoperative)
Replace
1. Pad or lining (Cracked or distorted)
Replace
Adjust
3. Disc (Scored)
Replace
4. Sliding pin (Worn)
Replace
5. Pad or lining (Dirty)
Brake fades
Repair
Bleed air
3. Pad or lining (Worn)
2. Installation bolt (Loose)
Noise from brake
Adjust
2. Pad or lining (Cracked or distorted)
1. Brake system (Fluid leaks)
Hard pedal but brake inefficient
Remedy
Bleed air
Clean
6. Pad or lining (Glazed)
Replace
7. Brake pad shim (Damaged)
Replace
1. Pad or lining (Worn)
Replace
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2. Master cylinder (Inoperative)
Replace
1. Pedal free play
Brake vibration, pulsation
Heavy pedal
(Halt)
Noisy electric motor and/or excessive
braking force after 2 - 3 consecutive
applications of brake pedal
(When accumulator pressure increase
rate is below 5bar/sec when sensor data
was inspected after connecting to AHB
module)
Excessive noise when pushing brake
pedal
Adjust
2. Master cylinder (Inoperative)
Replace
3. Caliper (Damaged)
Replace
4. Master cylinder cap seal
Replace
5. Damaged brake lines
Replace
1. Brake pedal stuck (Lack of grease)
Repair
2. IBAU (Inoperative)
Replace
1. AHB system (air in system)
Bleed air
2. PSU(Inoperative)
Replace
1. IBAU/PSU system (air in system)
Bleed air
The following operations may generate brake motor sound which is considered normal:
- Repeated pushing on brake pedal
- Pushing and releasing brake pedal during power off
- Opening driver side door
The following cases are normal although the brake pedal may seem abnormal:
- Noise when brake pedal is abruptly pushed
- Noise when brake pedal is consecutively pushed
Brake System
Operation and Leakage Check
Check all of the following items:
Component
Procedure
Integrated Brake Actuation Unit (IBAU) (A) and Check brake operation by applying the brakes during a test drive. If the brakes do not work properly, check the
Pressure Source Unit (PSU) (B)
IBAU and PSU. Replace IBAU and PSU as an assembly if it does not work properly or if there are signs of
leakage.
Piston cup and pressure cup inspection (B)
Check brake operation by applying the brakes. Look for damage or signs of fluid leakage. Replace the IBAU
as an assembly if the pedal does not work properly or if there is damage or signs of fluid leakage.
Brake hoses (C)
Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking.
Caliper piston seal and piston boots (D)
Check brake operation by applying the brakes.
Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes drag, or there is
damage or signs of fluid leakage, disassemble and inspect the brake caliper. Replace the boots and seals with
new ones whenever the brake caliper is disassembled.
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Bleeding of Brake System
AHB Brake System Bleeding procedure
• Do not reuse the drained fluid..
• Always use genuine DOT3/DOT4 brake fluid. Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.
• Make sure no dirt or other foreign matter is allowed to prevent contaminating the brake fluid.
• Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
• When bleeding air, make sure that the brake fluid is at least 10mm above the "MIN" line.
• To remove the reservoir tank cap to refill the brake fluid, always close the air shut-off valve of the SST.
Air Bleeding Tool Installation Procedure
To prevent the brake fluid reservoir tank from being damaged and to ensure the safety of workers, set the pressure of the gauge to the standard value
before installing the SST.
1. Before installing the SST on the vehicle, close the air shut-off valve (A) to adjust the pressure gauge to the standard value.
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For the safety of workers and correct pressure setting, make sure that the plug (B) is installed correctly.
2. After connecting an air hose and opening the air shut-off valve (A), adjust the pressure gauge (B) to the standard value.
Standard pressure value:0.3 ~ 0.5MPa (43.5 ~ 72.5psi)
3. Close the air shut-off valve (A) and remove the plug (B).
For safety of worker, make sure that the air shut offvalve is closed and remove the plug.
4. Remove the brake reservoir tank cap.
5. Install the cap (A) of SST (0k585-E8100) on the reservoir tank.
6. Make sure that the check valve (A) is closed and then connect SST (09580-3D100) (A) to the adapter (B).
Air Bleeding Tool Removal Procedure
1. To remove the SST (09580-3D100) from the vehicle,close the air shut-off valve (A) first.
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2. After disconnecting the air hose (B), bleed air in the reservoir tank by slowly opening the air shut-off valve (A).
To prevent backflow of brake fluid, be sure to open the air shut-off valve slowly and then bleed air in the reservoir tank.
3. Remove SST (09580-3D100) and the cap of SST(0k585-E8100) on the reservoir tank.
4. Install the brake reservoir tank cap.
AHB Brake System Bleeding Step 1 (IBAU ECU OFF)
IBAU filled with brake oil should be used for bleeding.
1. Disconnect the negative (-) battery terminal to turn off IBAU ECU.
2. Set the air bleeding tool (SST: 09580-3D100) and the cap of SST (0k585-E8100) to reservoir tank and apply pressure (0.3~0.5MPa (43.5 ~ 72.5psi)) to it.
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3. Initiate air bleeding on all bleed screws in the following sequence until air bubbles no longer appear in the fluid.
PSU IBAU (2 bleed srews) 4 wheels (15 seconds for each)
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4. Perform air bleeding while stepping on the brake pedal and opening bleed screws; then, close bleed screws and release the brake pedal. Perform this
procedure 10 times.
A. Bleed screw sequence : IBAU (2 bleed srews) 4 wheels
B. Repeat until air bubbles no longer appear in the fluid
C. Be cautious not to open the bleed screws too much as air may flow into the brake system.
AHB Brake System Bleeding Step 2 (IBAU ECU ON)
1. Connect the negative (-) battery terminal to turn on IBAU ECU.
2. Set the ECU S/W to air bleeding mode on the brake system.
Setting the ECU S/W to air bleeding mode in 30 seconds.
(1) After turning IGN ON with the engine start button, set the front wheels straight forward and the shift lever knob in Parking.
(2) With the VDC switch in the ""OFF"" position, press and release the brake pedal 10 times. Make sure to press the brake pedal more than 40 mm deep
and release fully.
(3) Turn off the engine start button, and then restart the engine and turn the VDC switch to the ""ON"" position by pressing down on the VDC OFF switch
for 3 sec.
The air bleeding mode is disabled in each of the following conditions:
(1) IGN OFF and shift lever knob in D/R/N
(2) Detecting DTC
(3) Brake fluid level under "MIN"
(4) "VDC off" switch turned off
3. Use the air bleeding tool (SST: 09580-3D100, 0K585-E8100) and feed oil pressure of 0.3 ~ 0.5MPa (43.5 ~ 72.5psi) into the reservoir.
While pushing the brake pedal halfway, loosen the bleed screws on 4 wheels to release the brake fluid, and then close the bleed screws. Repeat this 10
times and then release the pedal.
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4. Connect the GDS to the data link connector located underneath the dash panel to perform "Fluid Circulation Mode" on GDS.
Fluid Circulation Mode removes air bubbles in the brake fluid and releases into the air by circulating the brake fluid inside the IBAU to the reservoir tank.
Brake System
Components
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Brake System
Removal
1. Disconnect the brake fiuid level switch connector, and remove the reservoir cap.
2. Remove the brake fluid from the master cylinder reservior with a syringe.
Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
3. Remove the wheel & tire.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
4. Remove the brake hose mounting bracket bolt (A).
5. Disconnect the brake tube by loosening the tube flare nut (B).
Tightening torque:
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12.7 ~ 16.7 N.m (1.3 ~ 1.7 kgf.m, 9.4 ~ 12.3 lb-ft)
Front
Rear
6. Remove the brake hose clip (A).
7. Disconnect the brake hose from the brake caliper by loosening the bolt (A).
Tightening torque:
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
Front
Rear
Inspection
1. Check the brake tubes for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damage and fluid leakage.
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3. Check the brake tube flare nuts for damage and fluid leakage.
4. Check brake hose mounting bracket for crack or deformation.
Installation
1. Install in the reverse order of removal.
Use a new washer (A) whenever installing.
2. After installation, bleed the brake system.
(Refer to Brake system bleeding)
3. Check for brake fluid leaks.
Brake System
Components
1. Brake pedal stroke sensor
2. Stop lamp switch
Brake System
Removal
3. Brake pedal
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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the crash pad lower panel and reinforcing panel. (Refer to the Body group - crash pad)
3. Remove the lower duct (A).
4. Pull down steering column shaft after removing bolts and nuts. (Refer to the steering group - Steering columm & shaft)
5. Disconnect the stop lamp switch connector (A) and the brake pedal stroke sensor connector (B).
6. Remove the brake pedal member mounting nut (A).
7. Remove the snap pin (A) and clevis pin (B).
8. Remove the brake pedal member assembly mounting nuts (A) and then remove the brake pedal assembly.
Tightening torque:10.8 ~ 12.7 N.m (1.1 ~ 1.3 kgf.m, 8.0 ~ 9.4 lb-ft)
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Installation
1. Install in the reverse order of removal.
2. Check the brake pedal operation.
3. Conduct calibration after removing the brake pedal assembly.
Brake pedal sensor Calibration
The brake pedal sensor calculates the pedal full stroke according to the preset zero. Therefore, zeroing adjustment is necessary when first installed.
Calibration must be performed in the following cases:
• After changing the brake pedal assembly (you cannot change only the sensor)
• After changing the BAU (Brake Actuation Unit)
• When error codes C1380 (calibration) or C1379 (signal error) are detected.
• After bleeding IBAU & PSU lines.
Calibration procedure
The calibration must be done while the vehicle is parked without stepping on the brake pedal and while there is no vibration on the vehicle.
1. Connect the GDS. (CAN line or OBD connector)
2. Turn ignition switch ON.
3. Select calibration of the brake pedal sensor.
4. Follow prompts displayed on the GDS screen to complete brake pedal sensor calibration.
5. Turn ignition switch off after calibration procedure.
6. Confirm success or failure of calibration.
Stop lamp switch clearance adjustment
Removal
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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the crash pad lower panel and reinforcing panel. (Refer to the Body group - crash pad)
3. Remove the lower duct (A).
4. Pull down steering column shaft after removing bolts and nuts. (Refer to the steering group - Steering columm & shaft)
5. Disconnect the stop lamp switch connector (A) and the brake pedal stroke sensor connector (B).
6. Pull the locking plate (A) as indicated by the arrow.
7. Turn brake switch 45° counterclockwise and remove it.
Inspection
1. Check the stop lamp switch.
(1) Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is
pushed in and when it is released.
(2) The stop lamp switch is in good condition if there is no continuity when plunger is pushed.
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Installation
1. With brake pedal fully released, insert the brake switch fully in contact with brake pedal arm.
2. After inserting, turn the brake switch 45° clockwise, and then push in the locking plate to assemble.
3. Confirm the gap between brake switch and bracket.
Brake clearance (A):
1.0 ~ 2.0 mm (0.04 ~ 0.08 in.)
4. Connect the brake switch connector (A).
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Adjustment
Brake switch clearance adjustment
If the gap between brake switch and bracket does not fall between 1.0 ~ 2.0mm (0.04~ 0.08in), conform to the following:
1. Disconnect the brake switch connector (A).
2. Pull the locking plate (A) as indicated by the arrow.
3. Turn brake switch 45° counterclockwise and remove it.
4. With brake pedal fully released, insert the brake switch fully in contact with brake pedal arm.
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5. After inserting, turn the brake switch 45° clockwise, and then push in the locking place to assemble.
6. Confirm the gap between brake switch and bracket.
Brake clearance (A):
1.0 ~ 2.0 mm (0.04 ~ 0.08 in.)
7. Connect the brake switch connector (A).
Brake System
Components
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1. Guide rod bolt
2. Bleed screw
3. Caliper carrier
4. Caliper body
5. Inner pad shim
6. Brake pad
7. Pad retainer
Brake System
Removal
Brake caliper assembly
1. Remove the front wheel & tire.Remove the front wheel & tire.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
2. Loosen the hose eyebolt (C) and guide rod bolts (B) and then remove the front caliper body (A).
Tightening torque
Brake hose to caliper (C):
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
Guide rod bolts (B):
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
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3. Remove the pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).
4. Loosen the caliper mounting bolts (B) and then remove the caliper carrier (A).
Tightening torque :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
Front Wheel Brake disc
1. Remove the front wheel & tire.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
2. Loosen the guide rod bolt (B) and pivot the caliper body (A) up out of the way.
3. Remove the pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).
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4. Loosen the caliper mounting bolts (B) and then remove the caliper carrier (A).
Tightening torque :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
5. Remove the front brake disc by loosening the screws (A).
Tightening torque :
4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
Replacement
Front brake pads
1. Remove the front wheel & tire.
2. Loosen the guide rod bolt (B) and pivot the caliper body (A) up out of the way.
3. Replace pad shim (D), pad retainers (C) and brake pads (B) in the caliper carrier (A).
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4. Compress the piston into the caliper body using the SST (09581-11000).
5. Place the caliper body (A) on the caliper carrier and tighten the guide rod bolt (B).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
6. Install the front wheel & tire.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Inspection
Front brake disc thickness check
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, at the same distance (5mm) from the brake disc
outer circle.
Brake disc thickness
Standard: 23 mm (0.906 in)
Service Limit: 21 mm (0.827 in)
Deviation: Less than 0.005mm (0.0002in)
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4. If the level of wear exceeds the limit, replace the discs and pad assembly on the left and right of the vehicle.
Front Brake Pad Check
1. Check for the pad wear and if the measured pad thickness is below the specified value, replace the pad assembly.
Pad thickness
Standard value: 10.5 mm (0.413 in)
Service limit: 2.0 mm (0.0787 in)
2. Check that grease is applied to sliding contact points and inspect the pad and backing metal for damage.
Front brake disc runout check
1. Place a dial gauge at approximately 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit: 0.04 mm (0.0016 in.) or less (new one)
2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
Brake caliper assembly
1. Install in the reverse order of removal.
2. Compress the piston into the caliper body using the SST (09581-11000).
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• Do not hit the piston end with a hammer or pry directly against piston face with a screwdriver to push in the piston.
• Push in wood or a used pad to protect the piston end.
• When spreading a piston, the whole area of piston end face should be protected from the SST.
3. After installation, bleed the brake system. (Refer to Brake system bleeding)
Front Wheel Brake disc
1. Install in the reverse order of removal.
2. Compress the piston into the caliper body using the SST (09581-11000).
• Do not hit piston end by hammer or prying directly against piston face with screwdriver to push in piston.
• Use wood or a used pad to protect piston end.Pushing piston with piece of wood or used pad is recommended.
• When spreading a piston, all area of piston end face should be protected from using the SST.
Brake System
Components
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1. Guide rod bolt
2. Bleed screw
3. Caliper carrier
4. Caliper body
5. Brake pad
6. Pad retainer
Brake System
Removal
1. Remove the rear wheel & tire.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
2. Release parking brake (EPB).
3. Disconnect the electric parking brake actuator connector (A).
4. Remove the hose eyebolt (B). Loosen the caliper mounting bolts (C) and remove the rear caliper body (A).
The hose eyebolt (A) tightening torque :
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
The caliper mounting bolts (B) tightening torque :
63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)
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5. Remove the rear brake disc by loosening the screws (A).
Replacement
Rear brake pads
1.
2.
3.
4.
5.
6.
Remove the rear wheel & tire.
Connect the GDS to the data link connector located underneath the dash panel.
Ignition "ON" & Engine "OFF".
Release the electric parking brake.
Select vehicle name and EPB system.
Select the “PAD change mode”.
7. Perform the " PAD change mode (Before pad change)" procedure with GDS.
When disengaging while the motor is in operation, be sure to press down on the brake pedal.
8. Ignition "OFF".
9. Disconnect the electric parking brake actuator connector (A).
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10. Loosen the guide rod bolts (B) and then remove caliper body (A).
11. Replace pad retainers (C) and brake pads (B) in the caliper carrier (A).
12. Insert the piston in the cylinder using SST (09580-0U000).
13. Place the caliper body (A) on the caliper carrier and tighten the guide rod bolts (B).
Tightening torque:
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
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14. Connect the electric parking brake actuator connector (A).
15. Ignition "ON".
16. Select the “PAD change mode”.
17. Perform the " PAD change mode (Before pad change)"procedure with GDS.
Check that the parking brake operates normally.
18. IGN switch “OFF” and remove the GDS.
19. Install the rear wheel & tire.
Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Inspection
Rear brake disc thickness check
1. Check the brake pads for wear and fade.
2. Check the brake disc for damage and cracks.
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, at the same distance (5mm) from the brake disc
outer circle.
Brake disc thickness
Standard: 10 mm (0.393 in)
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Service limit: 8.4 mm (0.331 in)
Deviation: Less than 0.005mm (0.0002in)
4. If the level of wear exceeds the limit, replace the discs and pad assembly on the left and right of the vehicle.
Rear Brake Pad Check
1. Check for the pad wear and if the measured pad thickness is below the specified value, replace the pad assembly.
Pad thickness
standard value : 10 mm (0.394 in)
service limit : 2.0 mm (0.0787 in)
2. Check that grease is applied to sliding contact points and inspect the pad and backing metal for damage.
Rear brake disc runout check
1. Place a dial gauge at approximately 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
limit: 0.05 mm (0.0020 in.) or less (new one)
2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1. Install in the reverse order of removal.
2. Insert the piston in the cylinder using SST (09580-0U000).
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3. After installation, bleed the brake system.
(Refer to Brake system bleeding)
Brake System
Components
1. EPB Unit
2. EPB Switch
3. Brake Caliper
Brake System
Description
4. EPB Warning Lamp
5. Brake Warning Lamp
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Description of EPB
EPB is an electronic parking brake. Unlike existing parking systems that operate by brake pedals or levers, the EPB system sends a signal to the ECU when
the driver operates the EPB switch. The ECU then operates the EPB actuator with motor gears to push the piston in the caliper to generate braking force. The
main functions of EPB are as follows:
- Static application
- Emergency braking when hydraulic brake malfunctions
- Auto application
EPB Function
1. Switch Operation at Stationary Condition (Static Park)
A. Manually engage the parking brake by operating the EPB switch at stationary condition.
B. With the ignition switch ON, the parking brake is engaged by the Reduced Clamp Force on a slope of less than 8%.
C. Otherwise, it is always engaged by the Full Clamp Force.
2. Switch Release at Stationary Condition (Static Release)
A. Release the parking brake by manually operating the EPB switch at stationary condition.
B. To secure safety, it is only released with ignition switch ON and the brake pedal pressed.
3. Dynamic Emergency Braking (Dynamic Braking)
A. Electric Controlled Deceleration (ECD)
When operating the EPB switch while driving, the operation request is sent to VDC only when the switch is in operation so that hydraulic braking is
performed by the VDC instead of the EPB actuator.
B. Rear Wheel Unlocker (RWU)
: If the VDC does not normally operate (VDC Fail) when the EPB switch is operated while driving and wheel speed information can be obtained, the
EPB actuator will independently maintain the safe movement of the vehicle to perform braking only during the switch operation.
C. Slow Ramp Up (SRU)If the VDC does not normally operate (VDC Fail) when the EPB switch is operated while driving and wheel speed information
cannot be obtained, the EPB will independently and gradually increase the parking force to perform braking only during the switch operation.
gradually to perform braking only during the
4. Automatic Application of EPB Force (Auto Apply)
A. When the vehicle is stopped while the Auto Vehicle Hold (AVH) is switched ON, the EPB will be automatically applied after the engine has turned off.
5. Automatic Release of EPB Force (Drive Away Release)
A. The parking brake will be automatically released when pressing the accelerator pedal with the EPB engaged.
B. To secure safety for automatic release, it will be automatically released only when all of the following conditions are met:
1. Engine turned on
2. Seatbelt fastened
3. Door, trunk and hood closed
- To prevent the vehicle from being moved downwards on a slope way, it will be automatically released only when driving torque above specific level
based on the slope has been obtained.
6. Reapplication of EPB Force When Vehicle Moves Downwards (Roll Away Reclamp)
A. Additional EPB force is generated when a downward vehicle movement is detected after applying EPB force.
B. With the engine OFF, this function is enabled only when the wheel speed information can be received (i.e., for 3 minutes after the engine has turned
off).
7. P to X (Automatic Release of EPB Force for Gear Shifting)
When moving the gearshift lever from the P or N position to the D or R position, the parking brake will be automatically released.
However, it will be possible only with the engine ON and the brake pedal pressed, in order to secure safety for automatic release.
Brake System
EPB Circuit Diagram (1)
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EPB Circuit Diagram (2)
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EPB connector input/output
Pin
Description
Pin
1
W
C-CAN (High)
21
Description
G/B
Center Fascia Switch
(ElectronicParking Brake Switch (SW3))
2
Br
C-CAN (Low)
22
-
-
3
-
-
23
-
-
4
-
-
24
-
-
5
-
-
25
-
-
6
-
-
26
-
-
G
Center Fascia Switch
(ElectronicParking Brake Switch (SW2))
7
-
-
27
8
-
-
28
9
-
-
29
10
-
-
30
-
-
G/O
Center Fascia Switch
(ElectronicParking Brake Switch (SW4))
-
-
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11
-
-
31
-
12
-
-
32
-
-
13
-
-
33
R
Electronic Parking Brake Actuator LH (-)
Ground (GF05)
14
-
-
34
B
15
-
-
35
B
Ground (GF05)
16
-
-
36
G
Electronic Parking BrakeActuator RH (-)
17
18
19
20
-
-
37
L/R
Electronic Parking BrakeActuator RH (+)
R
Smart Junction Block
(Fuse - MODULE 2)
38
B
Electronic Parking BrakeActuator LH (+)
W
Center Fascia Switch
(ElectronicParking Brake Switch (SW1))
39
W
PCB Block (Fuse - EPB 1)
-
-
40
R
PCB Block (Fuse - EPB 2)
Brake System
Removal
1. Turn ignition OFF and disconnect the negative (-) battery cable.
2. Remove the floor console assembly.(Refer to Body - “Floor console assembly")
3. Disconnect the EPB control unit mounting nuts and then remove EPB control unit.
Tighten torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
4. Disconnect the EPB control unit connector (A).
Installation
1.
2.
3.
4.
Install in the reverse order of removal.
After replacing the EPB control unit with a new one, “Variant Coding” procedure must be performed.
Perform the “G-Sensor Calibration” with GDS.
Check that the brake operates normally by pushing the EPB switch more than 3 times after installing the EPB module.
Variant coding
1. Turn ignition "OFF" and connect GDS.
2. While ignition "ON" & engine "OFF", select vehicle name and EPB system.
3. Select EPB Variant coding mode.
4. Perform the "EPB Variant Coding" procedure with GDS.
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5. Complete the “Variant Coding” procedure.
Brake System
Removal
1. Turn ignition OFF and disconnect the negative (-) battery cable.
2. Remove the floor console upper cover.
(Refer to Body group - "Console")
3. Remove the EPB switch assembly.
Installation
1. Install the EPB switch assembly to the floor console upper cover.
2. After connecting the EPB switch connecter, install the floor console upper cover. (Refer to Body group - "Console")
3. Connect the negative (-) battery cable.
Brake System
Description
Regeneration Brake System
During deceleration or braking of an electric vehicle or HEV, the drive motor acts as an alternator and charges the battery by converting the vehicle’s kinetic
energy generated during braking into electrical energy.
Regenerative braking amount depends on the vehicle speed, battery SOC, etc.
Achieve significant improvement in fuel efficiency in city driving with repeated acceleration and deceleration.
Regenerative Braking Cooperation Control (RBC)
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The brake force application is distributed by controlling hydraulic braking. The total brake force output that the driver demands is achieved by combining
hydraulic and regenerative brakes. In the case of regenerative brake failure, the total brake force that the driver demands is supplied by the hydraulic brake
system.
The AHB system is composed of the Pressure Source Unit (PSU) and the Integrated Brake Actuation Unit (IBAU).
First, the PSU generates the hydraulic pressure required for braking.
Similar to the boosting effect when the driver steps on the brake pedal in a system equipped with a vacuum booster, the hydraulic pressure stored in the
cylinder is supplied to provide pressure throughout the entire brake line.
Second, the IBAU delivers pressure generated by the PSU to a caliper on each wheel. Also, it is connected to the brake pedal to detect the brake force
demanded by the driver and to generate the braking feeling.
The IBAU carries out the ABS, TCS, and ESC functions as in conventional vehicles.
AHB System Operation Principles
1. Initial Status
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High pressure (180 bar) is generated between the PSU and the IBAU at all times. Therefore, before removing the PSU or the IBAU, high pressure between
them should be reduced for safety by conducting"High pressure releasemode" of GDS connected to SOUL EV.
2. Brake operation
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Apply Mode: When the driver presses down the brake pedal, the IN valve turns ON, delivering the high pressure generated from PSU to the caliper by IBAU to
engage in brake operation.
The level of brake force is determined by the pedal simulator according to the measurement of the pedal stroke sensor signal.Release Mode: When the
driver releases the brake pedal, the OUT valve opens and the IN valve closes, returning the high pressure of brake oil back to PSU. At the same time,
the CUT valve turns ON to prevent backflow of brake oil into the IBAU.
2. Brake malfunction
When either PSU or IBAU is faulty, both IN and OUT valves will close and the CUT valve will turn off. In this case, brake force can only be generated by
pressing down the brake pedal manually.
Integrated Brake Actuation Unit (IBAU) System (1)
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Integrated Brake Actuation Unit (IBAU) System (2)
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Integrated Brake Actuation Unit (IBAU) System (3)
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Integrated Brake Actuation Unit (IBAU) System (4)
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IBAU connector input/output
Description
Description
1.
R
E/R Junction Block (Fuse - IBAU 1)
24.
-
-
2.
R
PSU Motor (+)
25.
-
-
3.
-
-
26.
-
-
4.
B
PSU Motor (Shield Ground 2)
27.
G
Rear Wheel Sensor LH (SIG)
5.
G
Smart Junction Block (Fuse - IBAU)
28.
B
Front Wheel Sensor LH (SIG)
6.
R
Brake Pedal Sensor(PDT Input (Power))
29.
L
Smart Junction Block(IPS Control Module)
7.
P
Brake Pedal Sensor(PDF Input (Power))
30.
Y
E/R Junction Block (Fuse - IBAU 2)
8.
G/O
Stop Signal Electronic Module(HAC Signal)
31.
B
Brake Pedal Sensor(PDF (Ground))
9.
-
-
32.
-
-
10.
G/Y
Brake Pedal Sensor(PDT (Ground))
33.
O
Rear Wheel Sensor LH (VCC)
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11.
B
PSU Motor (Shield Ground 1)
34.
Y
12.
-
-
35.
-
Rear Wheel Sensor RH (VCC)
-
G
Stop Signal Electronic Module
(Stop Lamp Signal)
13.
W
PSU Motor (-)
36.
14.
B
Ground (GE06)
37.
L
Stop Signal Electronic Module(Stop Lamp)
15.
-
-
38.
G
SRS Control Module(Local CAN (High))
16.
O/B
Crash Pad Switch(ESC OFF Switch)
39.
Br
SRS Control Module(Local CAN (Low))
Y
Smart Key Control Module
(Wheel Sensor Signal)
17.
P
Front Wheel Sensor LH (VCC)
40.
18.
Br
Front Wheel Sensor RH (VCC)
41.
-
-
19.
W
C-CAN (High)
42.
P
Front Wheel Sensor RH (SIG)
20.
Br
C-CAN (Low)
43.
B
Rear Wheel Sensor RH (SIG)
21.
-
-
44.
L
Stop Lamp Switch (B)
22.
W
Brake Pedal Sensor(PDT Output (Signal))
45.
-
-
23.
Br
Brake Pedal Sensor(PDF Output (Signal)
46.
B
Ground (GE06)
Brake System
Components
IBAU must not be disassembled.
1. ECU
2. Reservoir
Brake System
Removal
3. Master cylinder Assembly
4. Valve block
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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap.
Be sure to completely remove foreign substances around brake fluid reservoir and cap before opening the reservoir cap to prevent any contamination
of brake fluid and deterioration in braking performance.
3. Using a syringe, remove the brake fluid from the reservoir.
• Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
• To prevent dust entering the reservoir, the reservoir cap should be closed again after removing brake fluid.
4. Disconnect reservoir hose from the reservoir and IBAU connecter (A).
5. Disconnect the brake tube from the IBAU by loosening the tube flare nut (B).
Before removing the IBAU, high pressure in an accumulator of PSU should be reduced for safety by conducting "High pressure release mode" of
GDS connected to SOUL EV.
Tightening torque:
13.7 ~ 16.7 N.m (1.4 ~ 1.7 kgf.m, 10.1 ~ 12.3 lb-ft)
6. Remove the brake pedal assembly. (Refer to the brake system group - brake pedal)
7. Remove the IBAU mounting nuts (A) and then remove the IBAU.
Tightening torque:
12.7 ~ 15.7 N.m (1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft)
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Installation
1.
2.
3.
4.
Install in the reverse order of removal.
Check the brake pedal operation.
After filling the brake fluid in the reservoir, perform the air bleed. (Refer to the AHB system - AHB system air bleeding)
Conduct calibration after removing the brake pedal assembly. (Refer to the brake pedal - calibration)
Brake System
Components
PSU must not be disassembled.
1. Motor connector
2. Bracket
3. Block
4. Accumulator
5. Damper
6. Motor
Brake System
Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap.
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Be sure to completely remove foreign substances around brake fluid reservoir and cap before opening the reservoir cap to prevent any contamination
of brake fluid and deterioration in braking performance.
3. Using a syringe, remove the brake fluid from the reservoir.
- Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
- To prevent dust entering the reservoir, the reservoir cap should be closed again after removing brake fluid.
4. Remove the IBAU (Refer to the AHB system - Intergrated Brake Actuation Unit (IBAU))
5. Disconnect the connector (A) and after removing a mounting clip, disconnect the reservoir hose(B).
6. Disconnect the brake tube from the PSU by loosening the bolt (B).
Before removing the PSU, high pressure in an accumulator of PSU should be reduced for safety by conducting "High pressure release mode" of GDS
connected to SOUL EV.
Tightening torque:
13.7 ~ 16.7 N.m (1.4 ~ 1.7 kgf.m, 10.1 ~ 12.3 lb-ft)
7. After disconnecting a connecter, Loosen the PSU bracket bolts and remove the PSU.
Tightening torque:
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
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Installation
1. Install in the reverse order of removal.
2. Check the brake pedal operation.
3. After filling the brake fluid in the reservoir, perform the air bleed. (Refer to the AHB system - AHB system air bleeding)
4. Conduct calibration after removing the brake pedal assembly. (Refer to the brake pedal - calibration)
5. Tighten the PSU bracket bolts and brake tube to the specified torque.
6. Conduct calibration after removing or installing the PSU.
Pressure sensor Calibration
The pressure sensor mounted within the PSU calculates the pressure according to initial zeroing. Therefore, initial zero adjustment is required when installed
for the first time. After replacing the PSU (cannot replace sensor only), the calibration must be performed.
Calibration procedure
1. Connect the GDS. (CAN line or OBD connector)
2. Turn ignition switch on.
3. Press pressure sensor calibration button.
4. Pressure sensor calibration procedure is performed (Calibration recorded & DTC erased).
5. Turn ignition switch off and on after calibration procedure.
6. Confirm successful calibration.
Brake System
Components
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1. Front wheel speed sensor
2. Front wheel speed sensor connector
Brake System
Removal
1. Remove the front wheel & tire.
Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
2. Remove the front wheel speed sensor mounting bolt (A).
Tightening torque:
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
3. Disconnect the front wheel speed sensor connector (A).
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4. Loosen the mounting bolt (A) and then remove the front wheel speed sensor.
Tightening torque :
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
5. Install in the reverse order of removal.
Brake System
Components
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1. Rear wheel speed sensor
2. Extension cable assembly
Brake System
Removal
1. Remove the rear wheel & tire.
Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
2. Remove the rear wheel speed sensor.
(Refer to Driveshaft and axle - "Rear Hub - Carrier")
3. Install in the reverse order of removal.
Brake System
Description
The yaw rate and G sensor is included inside the air bag control module (SRSCM).
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electronically by the vibration change of plate fork inside
the yaw rate sensor.
If yaw velocity reaches the specific velocity after it detects the vehicle's yawing, the ESC control is reactivated.
The lateral G sensor senses vehicle's lateral G. A small element inside the sensor is attached to a deflectable lever arm by the lateral G
Direction and magnitude of lateral G loaded to vehicle can be known by the change in electrostatic capacity according to lateral G.
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Specifications
Description
Specification
Operating voltage
8 ~ 16V
Output signal
CAN Interface
Operating temperature
-40 ~ 85°C (-40 ~ 185°F)
Yaw-rate sensor
Measurement range
± 100°/sec
G sensor
Measurement range
± 1.8 g
Brake System
Removal
1.
2.
3.
4.
Remove the ignition key from the vehicle.
Disconnect the battery negative cable and wait for at least three minutes before beginning to work.
Disconnect the DAB, PAB, SAB, CAB and BPT connectors.
Remove the floor console.
(Refer to Body - "Floor console")
5. Remove the rear heating joint duct (A).
6. Pull up the lock of the SRSCM connector and disconnect the connector (A).
7. Remove the SRSCM mounting bolts(3EA) from the SRSCM, then remove the SRSCM.
Remarks
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Installation
1. Remove the ignition key from the vehicle.
2. Disconnect the battery negative cable and wait for at least three minutes before beginning to work.
3. Install the SRSCM with the SRSCM mounting bolts.
Tightening torque (SRSCM Mounting Bolt) :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.7 ~ 7.3 lb-ft)
• Use new mounting bolts when replacing the SRSCM after a collision.
• When installing the airbag wiring harness, ground points(C) must be installed.
4. Connect the SRSCM harness connector.
5. Install the rear heating joint duct.
6. Install the floor console.
(Refer to Body - "Floor console")
7. Reconnect the battery negative cable.
8. After installing the SRSCM, confirm proper system operation:
A. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
• SRSCM senses the vehicle rollover. SAB, CAB and BPT may be deployed if SRSCM was shaken up and down or left and right during IGN ON state.
For this reason, make sure that the IGN is turned OFF before removing the SRSCM from the vehicle.
• If the SRSCM is replaced always perform variant coding. Also, perform the lateral G sensor calibration.
(Refer to Restraint - "SRS Control Module")
G-Sensor Calibration
1.
2.
3.
4.
Turn ignition "OFF" and connect GDS.
While ignition "ON" & engine "OFF", select vehicle name and ESC system.
Perform G-sensor calibration.
Perform the "G-Sensor Calibration" procedure with GDS.
5. Complete the "G-Sensor Calibration" procedure.
Brake System
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Description
1. The ESP OFF switch is used by users to turn off the ESP system.
2. The ESP OFF lamp is on when ESP OFF switch is engaged.
Brake System
Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the lower crash pad switch assembly (A) by pushing it.
4. Disconnect the connectors (A) from the lower crash pad switch assembly.
5. Check the continuity between the switch terminals as the ESP OFF switch is engaged.
Brake System
Description
Installed in MDPS (Motor Driven Power Steering), the Steering Angle Sensor (SAS) sends signals to HECU through CAN communication line.
The SAS is used to determine turning direction and speed of the steering wheel.
The HECU uses the signals from the SAS when performing ESP-related calculations.
Components (Steering Angle Sensor, Torque Sensorm Failsafe relay, etc.) of the EPS system are located inside the steering column and EPS control unit
assembly. Steering column and EPS control unit assembly must not be disassembled for inspection or replacement (Refer to "ST (Steering system) Gr.").
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Body (Interior and Exterior)
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Body (Interior and Exterior)
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Body (Interior and Exterior)
Specifications
Items
Hood
Front Door
Rear Door
Type
Specification
Rear hinged, gas lifter type
Structure
Front hinged, frame door Structure
Regulator system
Wire drum type
Locking system
Pin-fork system
Construction
Front hinged, frame door Structure
Regulator system
Wire drum type
Locking system
Pin-fork system
Tail Gate
Type
Front hinged, gas lifter type
Seat Belts
Front
3 point type with Convertible Locking Retractor (C.L.R)
Rear
3 point type with Convertible Locking Retractor (C.L.R)
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Sealant
Applied parts
Bead width
Height : 13.5 mm (0.53 in.)
Panorama Sunroof
Width : 12 mm (0.47 in.)
Height : 12 mm (0.4724 in.)
Windshield Glass
Width : 8 mm (0.3150 in.)
Tightening Torque
Items
Front and rear doors
N.m
Kgf.m
lb-ft
Door hinge to body
34.2 ~ 41.2
3.5 ~ 4.2
25.3 ~ 30.4
Door hinge to door
15.9 ~ 19.5
21.6 ~ 26.5
2.2 ~ 2.7
Door checker to door
3.9 ~ 5.9
0.4 ~ 0.6
2.9 ~ 4.3
Door checker to body
16.7 ~ 21.6
1.7 ~ 2.2
12.3 ~ 15.9
Door glass mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Outside handle base mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Door channel mounting bolt
6.9 ~ 10.8
0.7 ~ 1.1
5.1 ~ 8.0
2.9 ~ 4.3
Door channel mounting nut
Tail gate
Hood
Seat
3.9 ~ 5.9
0.4 ~ 0.6
Door latch mounting bolts
7.8 ~ 10.8
0.8 ~ 1.1
5.8 ~ 8.0
Door module mounting bolts
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Door striker mounting bolts
16.7 ~ 21.6
1.7 ~ 2.2
12.3 ~ 15.9
Tail gate hinge to body
21.6 ~ 26.5
2.2 ~ 2.7
15.9 ~ 19.5
Tail gate hinge to tail gate
21.6 ~ 26.5
2.2 ~ 2.7
15.9 ~ 19.5
Tail gate latch mounting bolts
6.9 ~ 10.8
0.7 ~ 1.1
5.1 ~ 8.0
Tail gate striker mounting bolts
21.6 ~ 26.5
2.2 ~ 2.7
15.9 ~ 19.5
Hood hinge to body
21.6 ~ 26.5
2.2 ~ 2.7
15.9 ~ 19.5
Hood hinge to hood
21.6 ~ 26.5
2.2 ~ 2.7
15.9 ~ 19.5
Hood latch to body
6.9 ~ 10.8
0.7 ~ 1.1
5.1 ~ 8.0
Front seat mounting bolts
34.3 ~ 53.9
3.5 ~ 5.5
25.3 ~ 39.8
Front seat frame mounting bolts
44.1 ~ 53.9
4.5 ~ 5.5
32.5 ~ 39.8
Rear seat mounting bolts
16.7 ~ 25.5
1.7 ~ 2.6
12.3 ~ 18.8
Rear seat latch mounting bolts
19.6 ~ 29.4
2.0 ~ 3.0
14.5 ~ 21.7
Height adjuster mounting bolts
39.2 ~ 53.9
4.0 ~ 5.5
28.9 ~ 39.8
Front seat belt upper anchor mounting bolt
39.2 ~ 53.9
4.0 ~ 5.5
28.9 ~ 39.8
Front seat belt pretensioner mounting bolt
39.2 ~ 53.9
4.0 ~ 5.5
28.9 ~ 39.8
Rear seat belt retractor mounting bolt
39.2 ~ 53.9
4.0 ~ 5.5
28.9 ~ 39.8
Rear center seat belt retractor mounting nut
39.2 ~ 53.9
4.0 ~ 5.5
28.9 ~ 39.8
Seat belt buckle mounting bolt
39.2 ~ 53.9
4.0 ~ 5.5
28.9 ~ 39.8
Outside rearview mirror mounting nuts
6.9 ~ 10.8
0.7 ~ 1.1
5.1 ~ 8.0
Wiper arm
Wiper arm mounting nuts
22.6 ~ 26.5
2.3 ~ 2.7
16.6 ~ 19.5
Roof rack
Roof rack mounting nuts
3.9 ~ 4.4
0.4 ~ 0.45
2.9 ~ 3.3
Quarter fixed glass
Quarter fixed glass mounting nuts
3.9 ~ 4.4
0.4 ~ 0.45
2.9 ~ 3.3
Panorama sunroof mounting nuts
9.8 ~ 14.7
1.0 ~ 1.5
7.2 ~10.8
Panorama sunroof mounting bolts
19.6 ~ 29.4
2.0 ~ 3.0
14.5 ~ 21.7
Seat belt
Outside rearview mirror
Panorama sunroof
Body (Interior and Exterior)
Special Service Tools
Tool Name / Number
Hog ring clip installer
09880-4F000
Illustration
Description
Used to install hog ring clip
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• When removing & installing or inspecting the high
voltage battery terminals or wiring where spark may
happen.
• When working on the high voltage battery pack
assembly.
Face shield
Insulation mat
Insulation sheet
Body (Interior and Exterior)
Removed high voltage components are placed on the
insulation mat to prevent safety accidents.
High voltage components are covered with insulation
sheet to protect people not wearing personal protective
equipment from safety accidents.
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Troubleshooting
Symptom
Possible Cause
Remedy (Refer to page)
Water leaks from panorama
sunroof
Deteriorated roof lid weatherstrip
Replace
Excessive roof lid-to-body clearance and improperly fitted
weatherstrip
Adjust
Wind noise around panorama
sunroof
Loose or deformed deflector, gaps in body work
Retighten adjust or replace
Noise heard when opening/
closing panorama sunroof
Foreign particles lodged in guide rail
Check drive cable and guide rails
for foreign particles
Loose guide rails and lid
Motor runs but panorama sunroof Foreign particles lodged in guide rail
does not move or moves only
Incorrect engagement of motor pinion with drive cable
partially
Decrease in motor`s clutch slipping force
Retighten
Adjust or replace
Increased panorama sunroof sliding resistance or interference of
panorama sunroof with drive cables, weatherstrip, etc. due to
maladjustment of panorama sunroof
Noise in motor (clutch slipping
Incorrect engagement of motor pinion with drive cable
noise from motor when panorama
sunroof is fully opened or closed is
Worn out or damaged motor pinion bearing
considered normal)
Worn out or deformed drive cable
Check pinion installation and
Door glass fails to operate up and Incorrect window glass installation
down
Damaged or faulty regulator arm or regulator
Adjust position
Door does not open or close
completely
Hood does not open or close
completely
Water leaks through windshield
end rear window
Re-tighten motor
Replace motor assembly
Replace
Correct or replace
Incorrect door installation
Adjust position
Defective door check assembly
Correct or replace
Door hinge requires grease
Apply grease
Striker and latch not properly aligned
Adjust
Incorrectly installed hood
Adjust
Incorrect hood bumper height
Adjust
Defective seal
Fill with sealant
Defective flange
Correct
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Using a screwdriver or remover, remove the roof side moulding (A).
• Replace the roof side moulding with a new one.
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2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Using a screwdriver or remover, remove the fender garnish (A).
2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. After loosening the mounting screw, remove the A pillar garnish (A) using a screw driver.
• Replace the A pillar garnish with a new one.
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2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Remove the front tire.
2. After loosening the mounting clips and screws, remove the front wheel guard (A).
3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
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• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Remove the rear tire.
2. After loosening the mounting clips and screws, remove the front wheel guard (A).
3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Loosen the side sill moulding mounting screws.
2. Using a screwdriver or remover, remove the side sill moulding (A).
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3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Cowl top cover
Body (Interior and Exterior)
Replacement
1. Remove the cap (A), the nuts and the wiper arm (B).
Tightening torque :
22.6 ~ 26.5 N.m(2.3 ~ 2.7 kgf.m, 16.6 ~ 19.5 lb-ft)
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2. Remove the glue from both ends (A) of the hood weatherstrip.
3. Disconnect the cowl top cover nozzle hose (A).
4. Detach the clips, then remove the cowl top cover (A).
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5. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Components
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1. Main crash pad assembly
2. Crash pad side cover [LH]
3. Crash pad side cover [RH]
4. Crash pad lower panel
Body (Interior and Exterior)
Component Location
5. Knee bolster panel
6. Steering column shroud lower panel
7. Center support floor mounting bracket
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1. Cluster fascia panel
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Lower the steering wheel.
2. Using a screwdriver or remover, remove the cluster fascia panel (A).
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3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Center fascia panel
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Using a screwdriver or remover, remove the center fascia panel (A).
2. Disconnect the A/C & heater controller connectors (A).
3. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Crash pad lower panel
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the cowl side trim.
(Refer to Interior Trim - "Cowl Side Trim")
2. Using a screwdriver or remover, remove the crash pad side cover [LH] (A).
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3. After loosening the mounting screws, remove the crash pad lower panel (A) using a screw driver.
4. Disconnect the diagnosis connector (A).
5. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Glove box housing
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Using a screwdriver or remover, remove the crash pad side cover [RH] (A).
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2. Loosen the glove box housing mounting bolts (A).
3. After loosening the mounting screws, remove the crash pad lower panel (A) using a screw driver.
4. Disconnect the glove box lamp connector (A).
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5. Remove the glove box housing mounting clip (A).
• When installing glove box housing, be sure to insert lock pin (A) into wiring tape (B).
6. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Steering column shroud lower panel
2. Steering column shroud upper panel
Body (Interior and Exterior)
Replacement
[Steering column shroud lower panel]
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the crash pad lower panel.
(Refer to Crash Pad - "Crash Pad Lower Panel")
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2. After loosening the mounting screws, remove the steering column shroud lower panel (A) using a screw driver.
3. Install in the reverse order of removal.
• Replace any damaged clips.
[Steering column shroud upper panel]
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the cluster fascia panel.
(Refer to Crash Pad - "Cluster Fascia Panel")
2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
[LH]
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1. Crash pad side cover [LH]
[RH]
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1. Crash pad side cover [RH]
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
[LH]
1. Using a screwdriver or remover, remove the crash pad side cover [LH] (A).
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2. Install in the reverse order of removal.
• Replace any damaged clips.
[RH]
1. Using a screwdriver or remover, remove the crash pad side cover [RH] (A).
2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Crash pad center lower panel
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the floor console assembly.
(Refer to Floor Console - "Floor Console Assembly")
2. Remove the crash pad lower panel.
(Refer to Crash Pad - "Crash Pad Lower Panel")
3. Remove the glove box housing.
(Refer to Crash Pad - "Glove Box Housing")
4. After loosening the mounting screws, remove the crash pad center lower panel (A) using a screw driver.
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5. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Main crash pad assembly
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Disconnect the negative (-) battery terminal.
2. Remove both sides of the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
3. Remove both sides of the cowl side trim.
(Refer to Interior Trim - "Cowl Side Trim")
4. Remove the instrument cluster.
(Refer to Body Electrical System - "Instrument Cluster")
5. Remove the crash pad lower panel.
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(Refer to Crash Pad - "Crash Pad Lower Panel")
6. Remove the glove box housing.
(Refer to Crash Pad - "Glove Box Housing")
7. Remove the audio unit or AVN head unit.
(Refer to Body Electrical System - "Audio Unit")
(Refer to Body Electrical System - "AVN Head Unit")
8. Remove the crash pad center lower panel.
(Refer to Crash Pad - "Crash Pad Center Panel")
9. Remove the steering column shroud lower panel.
(Refer to Crash Pad - "Steering Column Shroud Panel")
10. Remove the steering wheel.
(Refer to Steering System - "Steering Wheel")
11. Remove the multifunction switch assembly.
(Refer to Body Electrical System - "Multifunction Switch")
12. Using a screwdriver or remover, remove the crash pad lower switch panel (A).
13. Disconnect the crash pad lower switch connector (A).
14. Using a screwdriver or remover, remove the crash pad center air vent panel (A).
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15. Disconnect the hazard switch connector (A).
16. After loosening the mounting screws, remove the charging notification lamp assembly using a screw driver.
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17. Disconnect the charging notification lamp connector (A).
18. Remove the twitter speaker.
(1) Insert the flat-tip screwdriver (C) to the hole (B) and remove the twitter speaker grill (A) by raising it with the screwdriver.
(2) Remove the twitter speaker grill (A).
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(3) After loosening the mounting screws, remove the twitter speaker (A).
(4) Disconnect the twitter speaker connector (A).
(5) After loosening the mounting screws, remove the crash pad side air vent panel (A) using a screw driver.
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19. Using a screwdriver or remover, remove the photo sensor (A).
20. Disconnect the photo sensor connector (B).
21. Loosen the mounting bolts (A).
22. Disconnect the passenger's airbag connector (B).
23. Remove the center fascia panel side's mounting clip (A).
24. After loosening the mounting bolts and nuts, remove the main crash pad assembly (B).
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• When installing main crash pad, be sure to pull out the twitter speaker connector wiring (A) through the hole on the side air vent
panel.
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25. Right before removing the main crash pad, slightly lift the main crash pad and remove the twitter speaker connector mounting clips (A)
located at both ends.
[LH]
[RH]
26. Install in the reverse order of removal.
• Make sure that the crash pad fits onto the guide pins correctly.
• Before tightening the bolts, make sure that the crash pad wire harnesses are not pinched.
• Make sure that the connectors are plugged in properly, and the antenna lead is connected properly.
• Enter the anti-theft code for the radio, and then enter the customer`s radio station presets.
Body (Interior and Exterior)
Component Location
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1. Cowl cross bar assembly
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Disconnect the negative (-) battery terminal.
2. Recover the refrigerant with a recovery/recycling/charging station.
3. When the engine is cool, drain the engine coolant from the radiator.
(Refer to Engine Mechanical System - “Coolant”)
4. Remove the cowl top cover.
(Refer to "Cowl Top Cover")
5. Remove the bolts and then pipe (A) from the evaporator core.
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6. Remove the bolts, and then expansion valve (A) from the evaporator core.
Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)
• Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
• When installing, replace with a new O-ring (B).
7. Loosen the cowl cross member mounting bolts (A).
8. Remove both sides of front seat assembly.
(Refer to Front Seat - "Front Seat Assembly")
9. Remove the main crash pad assembly.
(Refer to Crash Pad - "Main Crash Pad Assembly")
10. Disconnect the steering column connectors.
(Refer to Steering System - "Steering Column and Shaft")
11. Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
12. Remove the rear airduct assembly (A).
[LH]
(1) Remove the accelerator pedal fixed cap (A).
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(2) Remove the mounting bolt (A), and then remove the accelerator pedal module.
(3) Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).
(4) Remove the carpet floor.
(5) Loosen the nut and then remove the rear air duct assembly (A).
[RH]
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(1) Remove the floor carpet fixing clip (A), floor stripping and wire clips (B).
(2) Remove the carpet floor (A).
(3) Loosen the nut and then remove the rear air duct assembly (A).
13. Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift lever")
14. Disconnect the airbag control module (SRSCM) connector (A).
15. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
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16. Disconnect the passenger compartment junction box connectors (A).
17. Remove the passenger compartment junction box mounting clips (A).
18. Disconnect the multi box connectors (A).
[Driver's]
[Passenger's]
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19. Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]
[Passenger's]
20. Remove the drain hose (A).
21. Untie locking pin and then remove the high voltage PTC heater cable (A).
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(1) Pull the pin (A) in the direction of the arrow.
(2) Press the fixed pin (-) and then pull it while inserting the driver (A) into the hole (B).
22. After loosening the nuts and bolts, remove the cowl cross bar and heater & blower unit (A) altogether.
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23. Disconnect the heater & blower unit connectors.
(1) Remove the bolt (A) and clip (B), and then remove the high voltage PTC heater Ground.
(2) Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
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(3) Disconnect the blower unit (A) and then remove the wiring mounting clips.
(4) Disconnect PWM unit (A) and then remove the wiring mounting clips.
(5) Disconnect the blower motor (A) and then remove the wiring mounting clips.
(6) Disconnect the temperature control actuator (A) and duct sensor (B) connectors.
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(7) Disconnect the mode control actuator (A) connectors and then remove the wiring mounting clips.
(8) Remove the screw (A) and fastener (B) and then remove the virtual engine sound control unit.
24. Disconnect the heater & blower unit connectors.
(1) Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
(2) Disconnect the blower motor (A), temperature control actuator (B), mode control actuator (C) connectors and then remove the wiring
mounting clips.
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(3) Disconnect the evaporator temperature sensor (A), field effect transistor air conditioning resistor (B) connectors and then remove the
wiring mounting clips.
(4) Disconnect the cluster ionizer connector (A) and then remove the wiring mounting clips.
(5) Remove the heater & blower unit wiring mounting clips (A).
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25. Loosen the heater and blower unit mounting bolts (A) and then remove the mounting clips (B).
26. Remove the heater and blower unit (A) from the cowl cross bar (B) after loosening the mounting nuts.
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27. Install in the reverse order of removal.
• Make sure that the crash pad fits onto the guide pins correctly.
• Before tightening the bolts, make sure that the crash pad wire harnesses are not pinched.
• Make sure that the connectors are plugged in properly, and the antenna lead is connected properly.
• Enter the anti-theft code for the radio, and then enter the customer`s radio station presets.
Body (Interior and Exterior)
Component Location
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1. Fender assembly
Body (Interior and Exterior)
Replacement
• Be careful not to damage the fender and body.
• When removing the clips, use a clip remover.
1. Remove the head lamps.
(Refer to Body Electrical System - "Head Lamps")
2. Remove the A pillar garnish.
(Refer to Body Side Moulding - "A Pillar Garnish")
3. Remove the side sill moulding.
(Refer to Body Side Moulding - "Side Sill Moulding")
4. Using a clip remover, detach the clip, and remove the A pillar guard (A).
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5. Detach the clips and then remove the insulator pad (A).
6. Loosen the front wheel guard mounting screws and bolt.
7. Remove the front bumper side bracket (A) after loosening the screw and bolt.
8. After loosening the mounting bolts and nuts, remove the fender assembly (A).
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9. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove both sides of front seat assembly.
(Refer to Front Seat - "Front Seat Assembly")
2. Remove the rear seat assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
3. Remove the floor console assembly.
(Refer to Floor Console - "Floor Console Assembly")
4. Remove both sides of center pillar lower trim.
(Refer to Interior Trim - "Center Pillar Trim")
5. Remove both sides of cowl side trim.
(Refer to Interior Trim - "Cowl Side Trim")
6. Remove both sides of luggage side trim.
(Refer to Interior Trim - "Luggage Side Trim")
7. Remove the safety plug cover (A).
8. Remove the floor carpet assembly (B).
9. Remove the rear tunnel pad (B).
10. Install in the reverse order of removal.
• Replace any damaged clips.
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1. Floor carpet assembly
2. Rear tunnel pad
Body (Interior and Exterior)
Components
[A/T]
2. High voltage safety plug cover
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1. Console rear cover assembly
2. Floor console assembly
3. EPB switch assembly
4. Wiring assembly
5. Cup Hold assembly
6. Console side pad [LH]
Body (Interior and Exterior)
Component Location
7. Console side pad [RH]
8. Supplement cup hold
8. Ashtray
9. Floor console mat
10. Console storage box
11. Hole cover
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1. Floor console assembly
Body (Interior and Exterior)
Replacement
Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Pull in the direction of the arrow and remove the gear knob.
Escaping power : 55± 10kgf
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2. Using a screwdriver or remover, remove the console upper cover (A).
3. Disconnect the indicator connector (A), start/stop button switch connector (B) and multimedia jack connector (C).
4. Press the locking pin and disconnect EPB connector.
5. Remove the hole cover (A).
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6. Remove the console side cover (A) by pushing it backward.
[LH]
When installing, insert the front of console side cover (B) to hook (A).
[RH]
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When installing, insert the front of console side cover (B) to took (A).
7. After loosening the mounting screws and bolts, remove the floor console assembly (A).
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8. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Rear console cover
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the floor console assembly.
(Refer to Floor Console - "Floor Console Assembly")
2. Loosen the rear console cover mounting screws (A).
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3. Using a screwdriver or remover, remove the rear console cover (A).
4. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Console armrest
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. After loosening the mounting screws (A), remove the console armrest (B) using a screw driver.
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2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Components
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1. Front bumper cover
2. Front bumper side bracket
Body (Interior and Exterior)
Component Location
3. Charge door opener cover
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1. Front bumper cover
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Loosen the radiator upper cover mounting bolts and clips.
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2. Loosen the charge door opener cover mounting bolts (A).
3. Remove the engine room under cover.
(Refer to Motor System - "under cover")
4. Loosen the front bumper side's mounting screws to separate the side part.
• Remove the front bumper by pulling it out in the direction of the arrow while slightly lifting the side of the front bumper.
• When pulling out the front bumper, be careful not to damage the side part of the front bumper.
5. Push the locking pin to disconnect the fog lamp connector (A) and front bumper main connector (B).
[LH]
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[RH]
6. Remove the front bumper cover.
(1) Lift up the lower side of the front bumper cover (A).
(2) Remove the front bumper cover (A) by pushing it backward to release the locking pins (B) located upper side of the front bumper
cover.
(3) Remove the front bumper cover (A).
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7. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
1. Radiator grill
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
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• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front bumper.
(Refer to Front Bumper - "Front Bumper Cover")
2. Remove the charge door opener cover.
(Refer to body -"charge door opener cover" )
3. Loosen the screws and then remove radiator grill.
4. Install in the reverse order of removal.
• Replace the damaged clip.
Body (Interior and Exterior)
Components (1)
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1. Front door pull cap
2. Front door inside handle cap
3. Front door quadrant inner cover
4. Front door trim
5. Front door belt inside weatherstrip
Components (2)
6. Front door belt outside weatherstrip
7. Front door panel
8. Front door body side weatherstrip
9. Front door side weatherstrip
10. Front door hinge
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1. Front door module
2. Front door latch assembly
3. Front door panel
4. Front door checker assembly
5. Front door striker
6. Front door outside handle cover
7. Front door lock assembly
8. Front door outside handle pad
9. Front door outside handle
10. Front door window glass run
11. Front door window glass
Body (Interior and Exterior)
Adjustment
Glass Adjustment
• Check the glass run channel for damage or deterioration, and replace if necessary.
1. Remove the front door trim.
(Refer to Front Door - "Front Door Trim")
2. Remove the front door window glass mounting hole plug (A).
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3. After loosening the mounting bolts, carefully move the front door window glass (A) left and right to adjust the gap until the glass mounting
bolts are visible.
4. Check that the glass moves smoothly.
Door Striker Adjustment
• Make sure that the door latches securely without slamming it. If necessary, adjust the striker (A): The striker nuts are fixed. The
striker can be fine adjusted up and down, or in and out.
1. Loosen the screws (B) just enough for the striker to move.
Tightening torque :
(B) : 16.7 ~ 21.6 N.m (1.7 ~ 2.2 kgf.m, 12.3 ~ 15.9 lb-ft)
2. Tap on the striker with a plastic hammer to adjust the striker. The striker will not move much, but will give some adjustment.
3. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten
the screws and recheck.
Door Position Adjustment
• After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and bottom, door
edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the mounting bolts.
1. Check that the door and body edges are parallel.
2. Place the vehicle on a firm, level surface when adjusting the doors.
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3. Adjust at the hinges (A) :
A. Loosen the door mounting bolts slightly, and move the door in or out until it aligns flush with the body.
B. Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize the gaps.
C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.
Tightening torque :
(B) : 21.6 ~ 26.5 N.m (2.2 ~ 2.7 kgf.m, 15.9 ~ 19.5 lb-ft)
(C) : 34.2 ~ 41.2 Nm (3.5 ~ 4.2 kgf.m, 25.3 ~ 30.4 lb-ft)
4. Grease the pivot portions of the hinges indicated.
5. Check for water leaks.
Body (Interior and Exterior)
Component Location
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1. Front door trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Be careful not to scratch the door trim and other parts.
1. Using a screwdriver or remover, remove the front door quadrant inner cover (A).
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2. Using a flat-tip screwdriver (A), remove the front door inside handle cap (B) and front door pull cap (C).
3. After loosening the mounting screws, remove the front door trim (A) using a flat-tip screwdriver (B).
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4. Remove the front door inside handle cage (A).
5. Disconnect the outside rear view mirror switch connector (A) and power window switch connector (B).
6. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Make sure that the door locks/unlocks and opens/closes properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Remove the front door trim.
(Refer to Front Door - "Front Door Trim")
2. Loosen the front door inside handle mounting screws (A).
3. Using a flat-tip screwdriver (B), pull up the front door inside handle lock pin (C).
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4. Remove the front door inside handle (A).
5. Install in the reverse order of removal.
• Make sure that the door locks/unlocks and opens/closes properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Front door window glass
Body (Interior and Exterior)
Replacement
1. Remove the front door trim.
(Refer to Front Door - "Front Door Trim")
2. Remove the front door belt inside weatherstrip (A).
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3. Remove the front door window glass mounting hole plug (A).
4. Before removing the front door glass (C), loosen the mounting bolt (A) as loosely as possible and loosen the mounting bolt (B)
completely.
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
• Be careful not to drop the glass and/or scratch the glass surface.
• Use the door switch to align the mounting hole/bolt with the hole in the door.
• If unable to operate the window motor, remove the motor and align the hole by hand.
5. Carefully adjust the front door window glass (A) until you can see the bolts, then loosen them. Separate the glass from the glass run and
carefully pull the glass out through the window slot.
• When removing the front door glass, be careful not to separate the glass mounting bracket (B).
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6. Install in the reverse order of removal.
• Roll the glass up and down to see if it moves freely without binding.
• Adjust glass position as needed.
• Make sure that the door locks and opens properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Front door module
Body (Interior and Exterior)
Replacement
1. Remove the front door window glass.
(Refer to Front Door - "Front Door Window Glass")
2. Remove the front door outside handle.
(Refer to Front Door - "Front Door Outside Handle")
3. Disconnect the front door main connector (A).
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4. Loosen the front door outside handle base mounting bolt (A).
5. Disconnect the outside rear view mirror connector (A).
6. Loosen the front door latch (B) mounting screws.
7. After loosening the mounting bolts, remove the front door module (A).
Tightening torque :
Bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Screw : 7.8 ~ 10.8 N.m (0.8 ~ 1.1 kgf.m, 5.8 ~ 8.0 lb-ft)
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8. Remove the front door main connector mounting clips (A).
9. Remove the front door module wiring harness mounting clips (A).
10. Disconnect the front door latch connector (A) and then remove the mounting clip (B).
11. Disconnect the connectors and front door module wiring harness (A).
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12. Remove the front door latch assembly.
(Refer to Front Door - "Front Door Latch")
13. Remove the front speaker.
(Refer to Body Electrical System - "Speakers")
14. Remove the front power window motor.
(Refer to Body Electrical System - "Power Window Motor")
15. Install in the reverse order of removal.
• Apply sufficient grease on all rolling friction parts and springs.
• Make sure that connectors are connected properly and each rod is connected securely.
• Make sure that the door locks/unlocks and opens/closes properly.
Body (Interior and Exterior)
Component Location
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1. Front door outside handle
Body (Interior and Exterior)
Replacement
1. Remove the hole plug (A).
2. After loosening the mounting bolt, remove the front door outside handle cover (B).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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3. Remove the front door outside handle (A) by sliding it backward.
4. Disconnect the front door outside handle connector (A).
5. Install in the reverse order of removal.
• Be sure to install the outside handle pad (A) between the outside handle and the door panel.
• Make sure that the connectors are connected properly.
• Make sure that the door locks/unlocks and opens/closes properly.
Body (Interior and Exterior)
Component Location
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1. Front door latch
Body (Interior and Exterior)
Replacement
1. Remove the front door module.
(Refer to Front Door - "Front Door Module")
2. Remove the front door outside handle base (A) by pushing in the lock pins located in the back.
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3. Remove the front door outside handle connector wiring harness (A).
4. Remove the front door outside handle cable (A).
5. To remove the front door outside handle base connector (A), turn it counter clockwise and pull it forward.
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6. Remove the front door outside handle connector wiring harness (A).
7. Disconnect the front door latch connector (A).
8. Remove the front door latch assembly (B) by pulling it in the direction of the arrow.
9. Remove the front door inside handle cage (A).
10. Remove the front door inside handle cable (A) by pushing it backward.
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11. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Make sure that the door locks/unlocks and opens/closes properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Remove the front door trim.
(Refer to Front Door - "Front Door Trim")
2. Remove the front door belt inside weatherstrip (A).
3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Loosen the front door checker (B) mounting bolt.
Tightening torque :
16.7 ~ 21.6 N.m (1.7 ~ 2.2 kgf.m,12.3 ~ 15.9 lb-ft)
2. Detach the clips, and then remove the front door side weatherstrip (A).
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3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Components
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1. Front seat headrest
2. Front seat headrest guide
3. Front seat back cover
4. Front seat back heater
5. Front seat back pad
6. Front seat back lumbar assembly
7. Front seat back frame assembly
8. Front seat back board
9. Front seat cushion cover
10. Front seat cushion heater
11. Front seat cushion pad
12. Front seat cushion frame assembly
13. Front seat inside cover [RH]
14. Front seat inside cover [LH]
Body (Interior and Exterior)
Component Location
1. Front seat assembly
Body (Interior and Exterior)
Replacement
1. Loosen the front seat assembly mounting bolts (A).
Tightening torque :
34.3 ~ 53.9N.m (3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)
[Front]
15. Front seat shield outer cover
16. Height lever
17. Height lever cap
18. Recliner lever
19. Front seat shield inner cover
20. Front seat belt buckle
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[Rear]
2. Remove the front seat assembly (A).
3. Disconnect the airbag connector (A), seat heater & power seat switch connector (B) and front seat belt buckle connector (C).
[Driver's]
[Passenger's]
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4. Install in the reverse order of removal.
SEAT MOUNTING BOLT INSTALLATION PROCEDURE
• Set the seat in the rearmost position. Check that each slide is locked, and then temporarily tighten the front mounting bolts.
• Set the seat in the foremost position. Check that each slide is locked, and then completely tighten the rear mounting bolts.
• Set the seat in the rearmost position again and then completely tighten the front mounting bolts.
• Check that the seat operates to and fro smoothly and that the locking portion locks properly.
Body (Interior and Exterior)
Component Location
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1. Front seat shield outer cover
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Using a driver or a remover, open and remove the height lever (B).
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2. Loosen the screw locking pin (A), and then remove the recliner lever (B).
3. After loosening the screws, remove the shield outer cover (A).
4. Install in the reverse order of removal.
• Replace the damaged clip.
Body (Interior and Exterior)
Component Location
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1. Front seat shield inner cover
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front seat assembly.
(Refer to Front Seat - "Front Seat Assembly")
2. After loosening the mounting screws, remove the front seat shield inner cover (A).
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3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
1. Front seat back cover
Body (Interior and Exterior)
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Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front seat assembly.
(Refer to Front Seat - "Front Seat Assembly")
2. Push the lock pin (B) and pull out the front seat headrest (A) to remove it.
3. Remove the front seat lower protector (A).
4. Push the lock pins (B) to remove the front seat back board (A).
• Push the middle area of clip using a flat head screwdriver.
• Be careful not to damage the lock pins.
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5. Disconnect the connectors (A).
6. Detach the air ventilation seat back duct (B) by pulling the lock pin (A).
7. Pull out the hooks (A) from the front seat back frame.
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8. Remove the protectors (A) on both sides.
9. Turn the front seat back cover inside out. Then pull out the headrest guides (A) while pinching both side of the lower part of the guides.
10. Remove the front seat back cover (A) from the front seat back frame.
11. After removing the velcro tape (A) and hog-ring clips (B) on the front of seat back, remove the front seat back cover (C).
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12. Install in the reverse order of removal.
• To prevent wrinkles, make sure that the material is stretched evenly over the cover (B) before securing the hog-ring clips (A).
• Replace the hog-ring clips with new ones using special tool (C) (09880-4F000).
Body (Interior and Exterior)
Component Location
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1. Front seat cushion cover
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front seat shield inner cover.
(Refer to Front Seat - "Front Seat Shield Inner Cover")
2. Remove the front seat shield outer cover.
(Refer to Front Seat - "Front Seat Shield Outer Cover")
3. Remove the front seat lower protector (A).
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4. Disconnect the connectors (A).
5. Detach the air ventilation seat cushion duct (B) by pulling the lock pin (A).
6. Pull out the hooks (A) and front seat cushion cover (C) from the front seat cushion frame (B).
7. Remove the front seat cushion cover (A) from the front seat cushion frame.
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8. After removing the velcro tape (A) and hog-ring clips (B) from inside the front seat cushion cover, separate the front seat cushion cover
(C).
9. Install in the reverse order of removal.
• To prevent wrinkles, make sure that the material is stretched evenly over the cover (B) before securing the hog-ring clips (A).
• Replace the hog-ring clips with new ones using special tool (C) (09880-4F000).
Body (Interior and Exterior)
Component Location
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1. Front seat back frame assembly
2. Front seat cushion frame assembly
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front seat back cover.
(Refer to Front Seat - "Front Seat Back Cover")
2. Remove the front seat cushion cover.
(Refer to Front Seat - "Front Seat Cushion Cover")
3. Disconnect the connector (A).
4. After loosening the mounting bolts, separate the front seat back frame assembly (B) and front seat cushion frame assembly (C).
Tightening torque :
44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)
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5. Install in the reverse order of removal.
• Remove the side air bag to replace the side air bag installation seat.
(Refer to Restraint - "Side Airbag (SAB) Module")
• Before servicing, be fully aware of precautions and service procedures relevant to air bag.
(Refer to Restraint - "Side Airbag (SAB) Module")
Body (Interior and Exterior)
Components
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1. Front seat belt pretensioner
2. Height adjuster
3. Rear seat belt retractor
Body (Interior and Exterior)
Component Location
4. Rear seat belt buckle [LH]
5. Rear seat belt buckle [RH]
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1. Front seat belt pretensioner
Body (Interior and Exterior)
Replacement
• When installing the belt, make sure not to damage the pretensioner.
1. Remove the center pillar upper trim.
(Refer to Interior Trim - "Center Pillar Trim")
2. After loosening the mounting bolt, remove the front seat belt upper anchor (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.8 ~ 39.8 lb-ft)
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3. After disconnecting the pretensioner connector lock pin, remove the front seat belt pretensioner connector (A), loosen the mounting bolt,
and then remove the front seat belt pretensioner (B).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.8 ~ 39.8 lb-ft)
4. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Height adjust
Body (Interior and Exterior)
Replacement
1. Remove the front seat belt upper anchor.
(Refer to Front Seat Belt - "Front Seat Belt Pretensioner")
2. After loosening the mounting bolts, remove the height adjust (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8 lb-ft)
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3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Front seat belt buckle
Body (Interior and Exterior)
Replacement
1. Remove the front seat assembly.
(Refer to Front Seat - "Front Seat Assembly")
2. Disconnect the front seat belt buckle connector wiring (A).
3. After loosening the mounting bolt, remove the front seat belt buckle (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5kgf.m, 28.9 ~ 39.8 lb-ft)
4. Install in the reverse order of removal.
• Make sure the connector is plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Charge door opener cover
Body (Interior and Exterior)
Replacement
1. Remove the front bumper.
(Refer to Front Bumper - "Front Bumper Cover")
2. Loosen the screws, and then remove the charge door open cover lamp (A).
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3. Disconnect the notification for charge door open cover actuator (A) and charge door opener cover lamp connector (B).
4. Loosen the screws, and then remove the charge door opener cover assembly (A).
5. Install in the reverse order of removal.
Body (Interior and Exterior)
Adjustment
1. After loosening the hinge (A) mounting bolt, adjust the hood (B) clearance by moving it up and down, or left and right.
2. Adjust the hood height by turning the hood overslam bumpers (C).
3. After loosening the hood latch (D) mounting bolts, adjust the latch by moving it up and down, or left and right.
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Body (Interior and Exterior)
Component Location
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1. Hood assembly
Body (Interior and Exterior)
Replacement
• Be careful not to damage the hood and body.
• When removing and installing the hood, work in a group of two or more.
• When removing the clips, use a clip remover.
1. Using a screwdriver, lift the socket clips (A) up slightly on both ends of the lifter (B).
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2. After loosening the hood hinge (B) mounting bolts, remove the hood assembly (A).
Tightening torque :
21.6~26.5 N.m (2.2~2.7 kgf.m, 15.9~19.5 lb-ft)
3. Install in the reverse order of removal.
• Make sure that the hood locks/unlocks and opens/closes properly.
• Adjust the hood alignment.
Body (Interior and Exterior)
Replacement
• When removing and installing the hood lifter, work in a group of two or more.
• When removing the clips, use a clip remover.
1. Using a screwdriver (A), lift the socket clips (B) up slightly on both ends of the lifter (D), and then remove the lifter from the bracket (C).
2. Push the socket of the lifter into the bracket for installation.
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• Make sure that the hood locks/unlocks and opens/closes properly.
Body (Interior and Exterior)
Replacement
1. Using a clip remover, detach the clips, and remove the hood insulator pad (A).
• Be careful not to scratch the hood panel.
2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Remove the glue on both ends (A) of the hood weatherstrip (B).
• Be careful not to scratch the hood weatherstrip.
2. Install in the reverse order of removal.
Body (Interior and Exterior)
Component Location
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1. Hood latch release handle
Body (Interior and Exterior)
Replacement
1. Using a screwdriver or remover, remove the hood release handle (A).
• Use a 6mm hex bit to press the center until the handle easily pulls off the post.
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2. Install in the reverse order of removal.
• Make sure that the hood latch cable is connected properly.
• Make sure that the hood locks/unlocks and opens/closes properly.
Body (Interior and Exterior)
Component Location
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1. Hood upper latch assembly
Body (Interior and Exterior)
Replacement
1. Remove the charge door handle (A).
2. Hood lower latch assembly
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2. Loosen the front bumper upper cover mounting bolts and clips.
3. Gently lift the bumper upper cover.
4. Loosen the screw (B), and then remove the front bumper upper cover (A).
5. Loosen the bolts, and then remove the hood latch assembly (B).
6. Disconnect the hood latch cable (A) and remove the hood lower latch assembly (B).
7. Install in the reverse order of removal.
• Make sure that the hood latch release cable is connected properly.
• Make sure that the hood locks/unlocks and opens/closes properly.
• Adjust the latch alignment.
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Body (Interior and Exterior)
Components
1. Front pillar trim
2. Cowl side trim
3. Center pillar lower trim
4. Center pillar upper trim
Body (Interior and Exterior)
Component Location
5. Rear pillar trim
6. Front door scuff trim
7. Rear door scuff trim
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1. Front door scuff trim
2. Rear door scuff trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Using a screwdriver or remover, remove the front door scuff trim (A).
[Front]
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2. Remove the rear seat cushion assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
3. Using a screwdriver or remover, remove the rear door scuff trim (A).
[Rear]
4. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Cowl side trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front door scuff trim.
(Refer to Interior Trim - "Door Scuff Trim")
2. Remove the hood latch release handle.
(Refer to Hood - "Hood Latch Release Handle")
3. Slighty remove the front door body side weatherstrip.
4. Using a screwdriver or remover, remove the cowl side trim (A).
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5. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Front pillar trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front pillar trim.
(1) Use the following tool (A) to remove the front pillar trim.
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(2) Slightly spread open the front pillar trim and then place the tool (A) on the mounting clip (B) as in the picture below.
After placing the tool (A) on the mounting clip (B), push it forward.
• Once the front pillar trim has been removed, replace the clips to new ones.
(3) Remove the front pillar trim (A).
A. How to mount front pillar trim
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• Remove the mounting clip (A) by turning it clockwise.
2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Center pillar lower trim
2. Center pillar upper trim
Body (Interior and Exterior)
Replacement
[Center pillar lower trim]
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the front door scuff trim.
(Refer to Interior Trim - "Door Scuff Trim")
2. Remove the rear door scuff trim.
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(Refer to Interior Trim - "Door Scuff Trim")
3. Carefully remove the front door body side weatherstrip.
4. Carefully remove the rear door body side weatherstrip.
5. Remove the center pillar lower trim.
(1) To remove the seat belt anchor pretensioner (C), keep pushing the lock pin (A) in the direction of the arrow. Then, push in the lock
pin (B) and remove the seat belt.
(2) Using a screwdriver or remover, remove the center pillar lower trim (A).
6. Install in the reverse order of removal.
• Replace any damaged clips.
[Center pillar upper trim]
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the center pillar lower trim.
2. After loosening the mounting bolt, remove the center pillar upper trim (A).
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3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Rear transverse trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the trunk trim.
(1) Remove the shelf covering (A).
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(2) Remove the luggage cover board (A).
(3) Remove the luggage box (A).
2. Using a clip remover, detach the rear transverse trim mounting clips (A).
3. Using a screwdriver or remover, remove the rear transverse trim (B).
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4. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Luggage side trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat cushion assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
2. Remove the rear seat back assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
3. Remove the rear door scuff trim.
(Refer to Interior Trim - "Door Scuff Trim")
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4. Remove the rear transverse trim.
(Refer to Interior Trim - "Rear Transverse Trim")
5. After loosening the mounting bolts, remove the rear seat lower side bracket (A) [LH,RH].
6. Carefully remove the rear door body side weatherstrip.
7. Carefully remove the tail gate weatherstrip.
8. After loosening the mounting bolt, remove the rear seat belt lower anchir (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.8 ~ 39.8 lb-ft)
9. After loosening the mounting screw, remove the luggage side trim (A).
10. Install in the reverse order of removal.
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• Make sure that the connectors are connected in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
1. Rear pillar trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
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1. Remove the luggage side trim.
(Refer to Interior Trim - "Luggage Side Trim")
2. After loosening the mounting bolts, remove the rear pillar trim (A).
3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Outside rear view mirror
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Using a screwdriver or remover, remove the front door quadrant inner cover (A).
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2. Loosen the outside rear view mirror mounting screw (A).
3. After loosening the mounting bolts, remove the outside rear view mirror (A).
4. Disconnect the outside rear view mirror connector (B).
Tightening torque :
6.9~10.8 N.m(0.7~1.1 kgf.m, 5.1~8.0 lb-ft)
5. Install in the reverse order of removal.
• Make sure that the connectors are connected in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Inside rear view mirror
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
1. Remove the ECM mirror cover (A).
2. Disconnect the ECM mirror connector (B).
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3. Loosen the ECM mirror mounting screw (B).
4. Push the ECM mirror base up to remove the ECM mirror assembly (A).
5. Install in the reverse order of removal.
• Make sure that the connectors are connected in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Quarter fixed glass
Body (Interior and Exterior)
Removal
• Put on gloves to protect your hands.
• Use seat covers to avoid damaging any surfaces.
1. Remove the rear pillar trim.
(Refer to Interior Trim - "Rear Pillar Trim")
2. Loosen the quarter fixed glass (A) mounting nuts.
Tightening torque :
3.9 ~ 4.4 N.m (0.4 ~ 0.45 kgf.m, 2.9 ~ 3.3 lb-ft)
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3. Cut out the quarter fixed glass sealant using the utility knife.
• Do not scrape down to the painted surface of the body as damaged paint may interfere with proper bonding.
• Remove the rubber dam and fastereners from the body.
• Mask off surrounding surfaces before painting.
4. Remove the quarter fixed glass.
Installtion
1. Using a utility knife, scrape off the old adhesive to a thickness of about 2mm (0.08 in.) to smooth out the bonding surface around the
entire quarter fixed glass flange.
• Do not scrape down to the painted surface of the body as damaged paint may interfere with proper bonding.
• Mask off surrounding surfaces before painting.
• Remove the fasteners from the body.
2. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water away from the surface.
3. With a sponge, apply a light coat of glass primer along the edge of the quarter fixed glass as shown, then lightly wipe it off with gauze or
cheese cloth :
• Do not apply body primer to the quarter fixed glass and be careful not to mix up body and glass primer sponges.
• Never touch the primed surfaces with your hands as this may result in the adhesive not bonding to the quarter fixed glass
properly causing a leak after it has been installed.
• Keep water, dust and abrasive materials away from the primed surface.
4. With a sponge, apply a light coat of body primer to the original adhesive remaining around the flange. Let the body primer dry for at least
10 minutes.
• Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
• Never touch the primed surfaces with your hands.
5. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of
sealant around the edge of the quarter fixed glass (A) as shown. Apply the adhesive within 30 minutes after applying the glass primer.
Make a slightly thicker bead at each corner.
6. Install the quarter fixed glass.
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7. Let the adhesive dry for at least one hour, then spray water over the quarter fixed glass and check for leaks. Mark the leaking areas, let
the quarter fixed glass dry, then seal with sealant. Let the vehicle stand for at least four hours after installing the quarter fixed glass.
8. Reinstall all remaining removed parts.
9. Install the rear pillar trim.
Body (Interior and Exterior)
Components
1. Rear bumper cover
Body (Interior and Exterior)
Component Location
2. Rear bumper side bracket
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1. Rear bumper cover
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. After loosening the mounting screws, remove the rear combination lamp (A).
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2. Disconnect the rear combination lamp connector (A).
3. Loosen the rear bumper upper mounting clip (A).
4. Loosen the bolts and nuts, and then remove the rear under cover (A).
5. Loosen the mounting bolts (A).
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6. Disconnect the rear bumper main connector (A).
7. After loosening the rear bumper side's mounting screws and clip, separate the sides.
• Slightly lift up the side of the rear bumper and pull in the direction of the arrow to remove.
• When pulling out the front bumper, be careful not to damage the side part of the rear bumper.
8. Remove the rear bumper cover (A).
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9. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Rear bumper beam assembly
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear bumper cover.
(Refer to Rear Bumper - "Rear Bumper Cover")
2. Disconnect the bumper antenna connector (A) and license lamp connector (B).
3. Remove the joint connector mounting clip (C).
4. Remove the rear bumper wiring harness mounting clips (A).
5. Remove the mounting clips (B) and the rear bumper beam assembly (C), and then loosen the clips.
6. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Components (1)
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1. Rear door pull cap
2. Rear door inside handle cap
3. Rear door delta inner cover
4. Rear door trim
5. Rear door belt inside weatherstrip
6. Rear door panel
Components (2)
7. Rear door delta garnish
8. Rear door belt outside weatherstrip
9. Rear door body side weatherstrip
10. Rear door side weatherstrip
11. Rear door hinge
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1. Rear door module
2. Rear door latch assembly
3. Rear door panel
4. Rear door checker assembly
5. Rear door striker
6. Rear door outside handle cover
7. Rear door outside handle
8. Rear door outside handle pad
9. Rear door window glass run
10. Rear door channel
11. Rear door window glass
Body (Interior and Exterior)
Adjustment
Glass Adjustment
• Check the glass run channels for damage or deterioration, and replace them if necessary.
1. Remove the rear door trim.
(Refer to Rear Door - "Rear Door Trim")
2. Remove the rear door window glass mounting hole plug (A).
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3. Carefully move the rear door window glass (A) until the glass mounting bolt are visible, then loosen them.
4. Check that the glass moves smoothly.
Door Striker Adjustment
• Make sure that the door latches securely without slamming it. If necessary, adjust the striker (A) by moving it up and down or in and
out before fixing the striker nuts.
1. Loosen the screws (B) just enough for the striker to move.
Tightening torque :
(B) : 16.7 ~ 21.6 N.m (1.7 ~ 2.2 kgf.m, 12.3 ~ 15.9 lb-ft)
2. Lightly tap on the striker with a plastic hammer just enough to give some adjustment.
3. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten
the screws and recheck.
Door Position Adjustment
• After installing the door, check for a flush fit with the adjacent body panels, then check for equal gaps between the front, rear, and
bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the mounting bolts.
1. Check that the door and body edges are parallel.
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2. Place the vehicle on a firm, level surface when adjusting the doors.
3. Adjust at the hinges (A):
A. Loosen the door mounting bolts slightly, and move the door in or out until it aligns flush with the body.
B. Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize the gaps.
C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.
Tightening torque :
(B) : 21.6 ~ 26.5 N.m (2.2 ~ 2.7 kgf.m, 15.9 ~ 19.5 lb-ft)
(C) : 34.2 ~ 41.2 N.m (3.5 ~ 4.2 kgf.m, 25.3 ~ 30.4 lb-ft)
4. Grease the pivot portions of the hinges as indicated by the arrows.
5. Check for water leakage.
Body (Interior and Exterior)
Component Location
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1. Rear door trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Be careful not to scratch the door trim and other parts.
1. Using a screwdriver or remover, remove the rear door delta inner cover (A).
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2. Using a flat-tip screwdriver (A), remove the rear door inside handle cap (B).
3. After loosening the mounting screws, remove the rear door trim (A) using a flat-tip screwdriver (B).
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4. Remove the rear door inside handle cage (A).
5. Disconnect the power window switch connector (A).
6. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Make sure that the door locks/unlocks and opens/closes properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Remove the rear door trim.
(Refer to Rear Door - "Rear Door Trim")
2. Loosen the rear door inside handle mounting screws (A).
3. Using a flat-tip screwdriver (B), pull up the rear door inside handle lock pin (C).
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4. Remove the rear door inside handle (A).
5. Install in the reverse order of removal.
• Make sure that the door locks/unlocks and opens/closes properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Rear door window glass
Body (Interior and Exterior)
Replacement
1. Remove the rear door trim.
(Refer to Rear Door - "Rear Door Trim")
2. Remove the rear door belt inside weatherstrip (A).
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3. Hold down the power window glass switch to pull down the rear door window glass to the maximum level.
4. After loosening the mounting screws, remove the rear door belt outside weatherstrip (A).
5. After loosening the mounting screws, remove the rear door delta garnish (A).
6. Completely loosen the rear door channel mounting bolt and loosen the nuts as much as possible until they are just enough to hold the
rear door panel.
7. Slightly push the rear door channel in the direction of the arrow in the illustration below.
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8. Remove the rear door window glass mounting hole plug (A).
• Be careful not to drop the glass and/or scratch the glass surface.
• Use the door switch to align the mounting hole/bolt with the hole in the door.
• If unable to operate the window motor, remove the motor and align the hole by hand.
9. Carefully adjust the rear door window glass (A) until you can see the bolt, then loosen them. Separate the glass from the glass run and
carefully pull the glass out through the window slot.
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
10. Install in the reverse order of removal.
• Roll the glass up and down to see if it moves freely without binding.
• Adjust glass position as needed.
• Make sure that the door locks and opens properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Rear door module
Body (Interior and Exterior)
Replacement
1. Remove the rear door window glass.
(Refer to Rear Door - "Rear Door Window Glass")
2. Remove the rear door outside handle.
(Refer to Rear Door - "Rear Door Outside Handle")
3. After loosening the mounting bolt and nuts, remove the rear door channel (A).
Tightening torque :
Bolt : 6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
Nut : 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
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4. Disconnect the rear door main connector (A).
5. Loosen the rear door outside handle base mounting bolt (A).
6. Loosen the rear door latch (A) mounting screws.
7. After loosening the mounting bolts, remove the rear door module (B).
Tightening torque :
Bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Screw : 7.8 ~ 10.8 N.m (0.8 ~ 1.1 kgf.m, 5.8 ~ 8.0 lb-ft)
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8. Remove the rear door main connector mounting clips (A).
9. Remove the rear door module wiring harness mounting clips (A).
10. Disconnect the rear door latch connector (A) and then remove the mounting clip (B).
11. Disconnect the connectors and rear door module wiring harness (A).
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12. Remove the rear door latch assembly.
(Refer to Rear Door - "Rear Door Latch")
13. Remove the rear speaker.
(Refer to Body Electrical System - "Speakers")
14. Remove the rear power window motor.
(Refer to Body Electrical System - "Power Window Motor")
15. Install in the reverse order of removal.
• Apply sufficient grease on all rolling friction parts and springs.
• Make sure that connectors are connected properly and each rod is connected securely.
• Make sure that the door locks/unlocks and opens/closes properly.
Body (Interior and Exterior)
Component Location
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1. Rear door outside handle
Body (Interior and Exterior)
Replacement
1. Remove the rear door trim.
(Refer to Rear Door - "Rear Door Trim")
2. Remove the hole plug (A).
3. After loosening the mounting bolt, remove the rear door outside handle cover (B).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Remove the rear door outside handle (A) by sliding it backward.
5. Install in the reverse order of removal.
• Be sure to install the outside handle pad (A) between the outside handle and the door panel.
• Make sure that the door locks/unlocks and opens/closes properly.
Body (Interior and Exterior)
Component Location
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1. Rear door latch
Body (Interior and Exterior)
Replacement
1. Remove the rear door module.
(Refer to Rear Door - "Rear Door Module")
2. Remove the rear door outside handle base (A) by pushing in the lock pins located in the back.
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3. Remove the rear door outside handle cable (A).
4. Disconnect the rear door latch connector (A).
5. Remove the rear door latch assembly (B) by pulling it in the direction of the arrow.
6. Remove the rear door inside handle cage (A).
7. Remove the rear door inside handle cable (A) by pushing it backward.
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8. Install in the reverse order of removal.
• Make sure that the connectors are connected properly.
• Make sure that the door locks/unlocks and opens/closes properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Pull down rear door window glass by pressing the power window glass switch.
2. After loosening the mounting screws, remove the rear door belt outside weatherstrip (A).
3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Remove the rear door trim.
(Refer to Rear Door - "Rear Door Trim")
2. Remove the rear door belt inside weatherstrip (A).
3. Install in the reverse order of removal.
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• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
1. Loosen the rear door checker (B) mounting bolt.
Tightening torque :
16.7 ~ 21.6 N.m (1.7 ~ 2.2 kgf.m, 12.3 ~ 15.9 lb-ft)
2. Detach the clips, then remove the rear door side weatherstrip (A).
3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Components (1)
(Rear Seat Back Assembly)
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1. Rear seat headrest [LH]
2. Rear seat headrest [Center]
3. Rear seat headrest [RH]
4. Rear seat headrest guide [RH]
5. Rear seat headrest guide [Center]
6. Rear seat headrest guide [LH]
7. Rear seat folding bezel [LH]
8. Rear seat folding lever [LH]
9. Tether anchor garnish [LH]
10. Rear seat latch assembly [LH]
11. Rear seat latch rod support bracket [LH]
12. Rear seat back bush hinge [LH]
Components (2)
(Rear Seat Cushion Assembly)
13. Rear seat lower side bracket [LH]
14. Rear seat back striker [LH]
15. Rear seat back cover [LH]
16. Rear seat back pad [LH]
17. Tether anchor garnish [RH]
18. Rear seat back structure [LH]
19. Center hinge cover
20. Rear seat folding bezel [RH]
21. Rear seat folding lever [RH]
22. Rear seat latch rod support bracket [RH]
23. Rear seat latch assembly [RH]
24. Rear seat back striker [RH]
25. Rear seat back structure [RH]
26. Rear seat lower side bracket [RH]
27. Rear seat back bush hinge [RH]
28. Rear center seat belt retractor
29. Rear seat lower side bracket [Center]
30. Rear seat back cover [RH]
31. Rear seat back pad [RH]
32. Rear seat belt center cover
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1. Rear seat cushion cover
2. Rear seat cushion heater
Body (Interior and Exterior)
Component Location
3. Rear seat cushion pad
4. Heater ECU unit
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1. Rear seat back assembly [LH]
2. Rear seat back assembly [RH]
3. Rear seat cushion assembly
Body (Interior and Exterior)
Replacement
[Rear seat back assembly]
1. Detach the rear seat belt lower anchor (C) by pushing the lock pin (B) of center mini buckle (A) with flat-tip driver.
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2. Fold the rear seat back assembly.
3. Remove the center hinge cover (A).
4. Loosen the rear seat back mounting bolt (A).
Tightening torque :
16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3~18.8lb-ft)
5. Remove the rear seat back assembly (A).
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6. Install in the reverse order of removal.
[Rear seat cushion assembly]
1. Remove the trunk trim.
(1) Remove the luggage cover board (A).
(2) Remove the luggage box (A).
2. Remove the rear seat back[LH].
(Refer to Rear Seat - "Rear Seat Assembly")
3. Loosen the rear seat cushion mounting bolt (A).
Tightening torque :
16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3~18.8lb-ft)
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4. Remove the rear seat cushion assembly (A) by pushing it up.
5. Disconnect the heater cushion connector (A).
[LH]
[RH]
6. Install in the reverse order of removal.
Body (Interior and Exterior)
Component Location
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1. Rear seat back cover [LH]
2. Rear seat back cover [RH]
Body (Interior and Exterior)
Replacement
[LH]
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat back assembly [LH].
(Refer to Rear Seat - "Rear Seat Assembly")
2. Push the lock pin (B), remove the rear seat headrest (A).
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3. Using a screwdriver or remover, remove the rear seat folding bezel (A).
4. Using a screwdriver or remover, remove the rear seat belt center cover (A).
5. Using a screwdriver or remover, remove the tether anchor garnish (A).
6. Using a screwdriver or remover, remove the rear seat back bush hinge (A).
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7. Remove the protector (A) located in the bottom side of the rear seat back.
8. Zip off the rear seat back cover located in the side (A), and then pull it up.
9. Pull out the hooks (A) by the rear seat back frame.
10. Turn the rear seat back cover inside out. Then pull out the headrest guides (A) while pinching both sides of the lower part of the guides,
and remove them.
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11. Remove the rear seat back cover (A) from the rear seat back frame (B).
12. Remove the hog-ring clip (A) velcro tape (B) on the rear of seat back and then remove the rear seat back cover (C).
13. Install in the reverse order of removal.
• To prevent wrinkles, make sure the material is stretched evenly over the cover (B) before securing the hog-ring clips (A).
• Replace the hog-ring clips with new ones using special tool (C) (09880-4F000).
[RH]
• Put on gloves to protect your hands.
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• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat back assembly [RH].
(Refer to Rear Seat - "Rear Seat Assembly")
2. Push the lock pin (B), remove the rear seat headrest (A).
3. Using a screwdriver or remover, remove the rear seat folding bezel (A).
4. Using a screwdriver or remover, remove the tether anchor garnish (A).
5. Using a screwdriver or remover, remove the rear seat back bush hinge (A).
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6. Remove the protector (A) located in the bottom side of the rear seat back.
7. Zip off the rear seat back cover located in the side (A), and then pull it up.
8. Pull out the hook (A) by the rear seat back frame.
9. Turn the rear seat back cover inside out. Then pull out the headrest guides (A) while pinching both sides of the lower part of the guides,
and remove them.
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10. Remove the rear seat back cover (A) from the rear seat back frame (B).
11. Removing the hog-ring clips (A), Velcro tape (B) on the rear of seat back and then remove the seat back cover (C).
12. Install in the reverse order of removal.
• To prevent wrinkles, make sure the material is stretched evenly over the cover (B) before securing the hog-ring clips (A).
• Replace the hog-ring clips with new ones using special tool (C) (09880-4F000).
Body (Interior and Exterior)
Component Location
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1. Rear seat cushion cover
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat cushion assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
2. Loosen the heater ECU unit mounting screws (A).
3. Disconnect the heater ECU unit connector (B) and then remove the mounting clips (C).
[LH]
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[RH]
4. Remove the hog-ring clip (A), Velcro tape (C) on the rear of seat back and then remove the rear seat cushion cover (B).
[Rear side]
[Front side]
5. Install in the reverse order of removal.
• To prevent wrinkles, make sure the material is stretched evenly over the cover (B) before securing the hog-ring clips (A).
• Replace the hog-ring clips with new ones using special tool (C) (09880-4F000).
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Body (Interior and Exterior)
Component Location
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1. Rear seat latch assembly
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat back cover [LH]or [RH].
(Refer to Rear Seat - "Rear Seat Back Cover")
2. After loosening the mounting bolts, then remove the rear seat latch (A).
Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
3. Remove the rear seat latch rod (A) to direction of the arrow.
4. Install in the reverse order of removal.
Body (Interior and Exterior)
Component Location
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1. Rear seat folding lever
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat back cover [LH]or [RH].
(Refer to Rear Seat - "Rear Seat Back Cover")
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2. After loosening the mounting screws, then remove the rear seat folding lever (A).
3. Remove the rear seat latch rod (A) to direction of the arrow.
4. Install in the reverse order of removal.
Body (Interior and Exterior)
Component Location
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1. Rear seat belt retractor
Body (Interior and Exterior)
Replacement
• When installing the belt, be careful not to damage the retractor.
1. Remove the rear pillar trim.
(Refer to Interior Trim - "Rear Pillar Trim")
2. Loosen the rear seat belt upper anchor (A) mounting bolt.
3. After loosening the mounting bolt, remove the rear seat belt retractor (B).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.8 ~ 39.8 lb-ft)
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4. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Rear center seat belt retractor
Body (Interior and Exterior)
Replacement
• When installing the belt, be careful not to damage the retractor.
1. Remove the rear seat back cover [LH].
(Refer to Rear Seat - "Rear Seat Back Cover")
2. After loosening the mounting nut, remove the rear center seat belt retractor (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.8 ~ 39.8 lb-ft)
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3. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Rear seat belt buckle [LH]
2. Rear seat belt buckle [RH]
Body (Interior and Exterior)
Replacement
[LH]
1. Detach the rear seat belt lower anchor (C) by pushing the lock pin (B) of center mini buckle (A) with flat-tip driver.
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2. Remove the rear seat cushion assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
3. Loosen the mounting bolt, and then remove the rear seat belt buckle [LH] (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.8 ~ 39.8 lb-ft)
4. Install in the reverse order of removal.
[RH]
1. Remove the rear seat cushion assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
2. Loosen the mounting bolt, and then remove the rear seat belt buckle [RH] (A).
Tightening torque :
39.2 ~ 53.9 N.m (4.0 ~ 5.5 kgf.m, 28.8 ~ 39.8 lb-ft)
3. Install in the reverse order of removal.
Body (Interior and Exterior)
Components (1)
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[General Type]
1. Roof trim
2. Sunvisor [LH]
Body (Interior and Exterior)
Component Location
3. Sunvisor [RH]
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1. Sunvisor
2. Retainer
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Loosen the mounting screws, and then remove the sunvisor (A) and retainer (B).
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2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Assist handle
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the caps (A) and screws, and then remove the assist handle (B).
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2. Install in the reverse order of removal.
Body (Interior and Exterior)
Component Location
1. Roof Trim Assembly
Body (Interior and Exterior)
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Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
2. Remove both sides of the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
3. Remove both sides of the center pillar upper trim.
(Refer to Interior Trim - "Center Pillar Trim")
4. Remove both sides of the rear pillar trim.
(Refer to Interior Trim - "Rear Pillar Trim")
5. Remove both sides of the sunvisor and retainer.
(Refer to Roof Trim - "Sunvisor")
6. Remove both sides of the assist handle.
(Refer to Roof Trim - "Assist Handle")
7. Remove the overhead console lamp.
(Refer to Body Electrical System - "Overhead Console Lamp")
8. Remove the room lamp.
(Refer to Body Electrical System - "Room Lamp")
9. Recline the front seat towards the rear of the vehicle as far back as possible.
10. Remove the auto defog sensor cover (A).
11. Remove the ECM mirror cover (A), and then remove the auto defog sensor connector (B).
12. Disconnect the ECM mirror connector (B).
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13. Disconnect the roof trim main connector (A) and the mounting clips (B) in the front pillar.
[Driver's]
[Passenger's]
14. Using a clip remover, detach the roof trim assembly mounting clips (A).
15. Carefully remove the tail gate weatherstrip.
16. Carefully lower the rear side of the roof trim.
17. To remove the roof trim, press the lock pin (A) in the direction of the arrow.
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18. Before removing the roof trim, slightly lower the roof trim and disconnect the roof antenna connectors (A).
19. Remove the roof trim assembly (A) from the vehicle through the tail gate.
20. Remove the room lamp.
(Refer to Body Electrical System - "Room Lamp")
21. Remove roof trim wiring harness (A) from the roof trim assembly (B).
• Take care not to damage the roof trim wiring harness (A) when removing.
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1. When installing the roof trim wiring harness (A) on the roof trim (B), keep applying the hot melt using a hot melt gun tool.
2. Attach the anti-noise pad (C) on the roof trim (B) to prevent noise.
22. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Adjustment
1. After loosening the tail gate hinge (A) mounting bolt, adjust the tail gate by moving it up and down, or right and left.
2. Adjust the tail gate height by turning the tail gate overslam bumpers (B).
3. After loosening the tail gate striker (C) mounting bolts, adjust the tail gate striker by moving it up and down, or right and left.
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Body (Interior and Exterior)
Component Location
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1. Tail gate assembly
Body (Interior and Exterior)
Replacement
• Wear gloves to protect hands from injury.
• When removing and installing the tail gate, work in a group of two or more.
1. Remove the tail gate trim.
(Refer to Tail Gate - "Tail Gate Trim")
2. Disconnect the washer nozzle hose (A).
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3. Disconnect the connectors (A) and tail gate wiring harness (B).
4. Loosen the ground bolts (C).
5. After loosening the mounting bolts, remove the tail gate assembly (D).
Tightening torque :
21.6~26.5 N.m (2.2~2.7 kgf.m, 15.9~19.5 lb-ft)
6. Using a screwdriver, lift the socket clips (A) up slightly on both ends of the tail gate lifter (B).
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7. Install in the reverse order of removal.
• Make sure that the tail gate locks/unlocks and opens/closes properly.
• Adjust the tail gate alignment.
• Make sure that the connectors are connected properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Tail gate trim
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. After loosening the mounting screws, remove the tail gate trim (A).
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2. Install in the reverse order of removal.
• Replace any damaged clips.
Body (Interior and Exterior)
Component Location
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1. Tail gate latch assembly
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Remove the tail gate trim.
(Refer to Tail Gate - "Tail Gate Trim")
2. After loosening the mounting bolts, remove the tail gate latch assembly (A).
Tightening torque :
6.9~10.8 N.m (0.7~1.1 kgf.m, 5.1~8.0 lb-ft)
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3. Disconnect the tail gate latch connector (A).
4. Install in the reverse order of removal.
• Make sure that the tail gate locks/unlocks and opens/closes properly.
• Adjust the tail gate alignment.
• Make sure that the connectors are connected properly.
Body (Interior and Exterior)
Component Location
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1. Tail gate back panel
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Take care not to scratch the body surface.
1. Remove the tail gate trim.
(Refer to Tail Gate - "Tail Gate Trim")
2. Disconnect the back view camera connector (A).
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3. Loosen the tail gate back panel mounting nuts (A).
4. Using a screwdriver or remover, remove the tail gate back panel (A).
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5. Install in the reverse order of removal.
• Make sure that the connectors are plugged in properly.
• Replace any damaged clips.
Body (Interior and Exterior)
Replacement
• Take care to not let the tail gate fall on you as the lifts are removed. Have a helper hold the tail gate open, or use a secure method
to hold it open.
1. Using a screwdriver (A), lift up slightly the socket clips (B) of both ends on the lifter (D), and then remove the lifter from the bracket (C).
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2. Install in the reverse order of removal.
• Make sure that the tail gate locks and opens properly and locks securely.
Body (Interior and Exterior)
Replacement
1. Remove the tail gate weatherstrip (A).
• Do not apply sealant to the body.
2. Install in the reverse order of removal.
• Install the weatherstrip aligned with center line (B).
Body (Interior and Exterior)
Replacement
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Remove the rear seat cushion assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
2. Remove the rear seat back assembly.
(Refer to Rear Seat - "Rear Seat Assembly")
3. Remove the rear door scuff trim.
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4.
5.
6.
7.
8.
9.
(Refer to Interior Trim - "Door Scuff Trim")
Remove the luggage cover board (A).
Remove the luggage box (B).
Remove the rear luggage mat (C).
Using a screwdriver or remover, remove the rear transverse trim (D).
After loosening the mounting screws, remove the luggage side trim (E).
Install in the reverse order of removal.
• Replace any damaged clips.
1. Luggage cover board
2. Luggage box
3. Rear luggage mat
4. Rear transverse trim
Body (Interior and Exterior)
Components
5. Luggage side trim [LH]
6. Luggage side trim [RH]
7. Shelf covering
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1. Windshield glass
Body (Interior and Exterior)
Removal
• Put on gloves to protect your hands.
• Use seat covers to avoid damaging any surfaces.
1. Remove both sides of the front pillar trim.
(Refer to Interior Trim - "Front Pillar Trim")
2. Remove both sides of the A pillar garnish.
(Refer to Body Side Moulding- "A Pillar Garnish")
3. Remove the cowl top cover.
(Refer to "Cowl Top Cover")
2. Windshield glass moulding
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4. Remove the inside rear view mirror assembly.
(Refer to Mirror - "Inside Rear View Mirror")
5. Remove the LDWS unit.
(Refer to Body Electrical System - "Lane Departure Warning System (LDWS) Unit")
6. Cut out the adhesive using a utility knife (A).
• Use a utility knife with blade length of 8-12 inches.
7. Cut off the sealant on the edge (B) by pulling the piano wire (A) to the left and right.
8. If the piano wire (A) is visible from the chassis, push it into the edges.
9. Cut off the sealant on (A-A), (B-B) and (C-C) by pulling the piano wire (A) to the left and right.
• Put on gloves to protect your hands.
• Be careful not to burn your hands as friction heat may be generated while working on the wires.
• Be careful not to disconnect the piano wire.
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10. Remove the windshield glass (B) carefully using the glass holder (A).
Installtion
1. Using a utility knife, scrape off and smooth out old adhesives to a thickness of about 2mm (0.08 inc.) on the bonding surface around the
entire windshield opening flange:
A. Do not scrape down to the painted surface of the body as damaged paint may interfere with proper bonding.
• Remove the rubber dam and fastereners from the body.
• Mask off surrounding surfaces before painting.
2. Clean the bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water away from the surface.
3. After installing the spacer (A), temporarily install the windshield glass (B) by positioning it in the center and place the alignment mark (C).
4. Peel off the tape from the windshield glass moulding (A) and install the moulding on the windshield glass (B).
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5. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body
primer dry for at least 10 minutes.
• Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
• Never touch the primed surfaces with your hands.
• Mask off the dashboard before painting the flange.
6. Apply a light coat of glass primer to the outside of the fasteners.
• Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass properly, causing a leak after
the windshield glass is installed.
• Do not apply body primer to the glass.
• Keep water, dust, and abrasive materials away from the primer.
7. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of
adhesive (B) around the edge of the windshield glass (A) between the fastener and moulding as shown. Apply the adhesive within 30
minutes after applying the glass primer. Make a slightly thicker bead at each corner.
Sealant Bead width
Height : 12 mm (0.4724 in.)
Width : 8 mm (0.3150 in.)
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8. Use suction cups (A) to hold the windshield glass (B) over the opening, align it with the alignment marks (C) as in step 15, and set it
down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around. Do not open or
close the doors until the adhesive is dry..
9. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the windshield, wipe
with a soft shop towel dampened with alcohol.
10. Let the adhesive dry for at least one hour, then spray water over the roof and check for leaks. If a leak occurs, let it dry, then seal with
sealant :
A. Let the vehicle stand for at least four hours after windshield installation. If the vehicle must be driven within 4 hours, it must be driven
slowly.
B. Keep the windshield dry for the first hour after installation.
11. Install the LDWS unit.
12. Install the inside rear view mirror assembly.
13. Install the cowl top cover.
14. Install the A pillar garnish.
15. Install the front pillar trim.
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Body Electrical System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Body Electrical System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Body Electrical System
General Troubleshooting Information
Before Troubleshooting
1. Check applicable fuses in the appropriate fuse/relay box.
2. Using KIA approved battery tester, check the battery condition. Check the battery for damage and clean / tight connections.
(Refer to Engine Electrical System - "Battery")
• Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you will damage the alternator
diodes.
• Do not attempt to crank the engine with the battery ground cable loosely connected or you will severely damage the wiring.
3. Check the alternator belt tension (D).
Handling Connectors
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1. Make sure the connectors are clean and have no loose wire terminals.
2. Make sure multiple cavity connectors are packed with grease (except watertight connectors).
3. All connectors have push-down release type locks (A).
4. Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component. This clip has a
pull type lock.
5. Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket
(A).
6. Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
7. Always reinstall plastic covers.
8. Before connecting connectors, make sure the terminals (A) are in place and not bent.
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9. Check for loose retainer (A) and rubber seals (B).
10. The backs of some connectors are packed with grease. Add grease if necessary. If the grease (A) is contaminated, replace it.
11. Insert the connector all the way and make sure it is securely locked.
12. Position wires so that the open end of the cover faces down.
Handling Wires And Harnesses
1. Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
2. Remove clips carefully; don't damage their locks (A).
3. Slip pliers (A) under the clip base and through the hole at an angle, and then squeeze the expansion tabs to release the clip.
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4. After installing harness clips, make sure the harness doesn't interfere with any moving parts.
5. Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws
and bolts.
6. Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
Testing And Repairs
1. Do not use wires or harnesses with broken insulation.
Replace them or repair them by wrapping the break with electrical tape.
2. After installing parts, make sure that no wires are pinched under them.
3. When using electrical test equipment, follow the manufacturer's instructions and those described in this manual.
4. If possible, insert the remover tool from the wire side (except waterproof connector).
5. Use a probe with a tapered tip.
Refer to the user's guide in the wiring repair kit (Pub No. : TRK 015.)
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Five-step Troubleshooting
1. Verify the complaint
Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not begin disassembly or
testing until you have narrowed down the problem area.
2. Analyze the schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by tracing the current paths from the power feed through the circuit components to ground.
If several circuits fail at the same time, the fuse or ground is a likely cause.
Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of the problem.
3. Isolate the problem by testing the circuit.
Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient
troubleshooting.
Test for the most likely cause of failure first. Try to make tests at points that are easily accessible.
4. Fix the problem
Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.
5. Make sure the circuit works
Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse,
be sure to test all of the circuits on the fuse. Make sure no new problems turn up and the original problem does not recur.
Battery Reset
Description
When reconnecting the battery cable after disconnecting, recharging battery after discharged or installing the memory fuse located on the
driver's side panel after removing, be sure to reset systems mentioned on the below table.
In addition, when replacing or reinstalling their fuses after removing, they should be reset according to the below table. Please refer to the
below table when servicing.
System
Resetting
Auto up/down
window
Whenever the battery is disconnected, discharged or the related fuse is replaced or reinstalled, reset the Auto
up/down window system according to the procedure below.
1) Turn the ignition switch to the ON position.
2) Pull up the power window switch in order that the window can close completely, and then keep pulling up the
power switch for about 1 second.
Panoramaroof
Whenever the battery is disconnected, discharged or the related fuse is replaced or reinstalled, the
panoramaroof system must be reset according to the procedure below.
1) Turn the ignition key to the ON position and then close the panoramaroof completely.
2) Release the panoramaroof control lever.
3) Press and hold the CLOSE button for more than 10 seconds until the sunroof has moved slightly.
4) Release the panoramaroof control lever.
5) Press and hold the CLOSE button once again until the sunroof do as follows.
• Tilt → Slide Open → Slide Close
Then, release the lever.
6) Reset procedure of panorama system is finished.
Trip computer
When the battery is disconnected and reconnected, the set functions of the trip computer become initialized. So,
you need to explain this information to the customer.
Clock
Audio
Whenever the battery terminals or related fuses are disconnected, you must reset the time in audio head unit.
(Refer to Audio owner's manual)
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When the battery is disconnected and reconnected, the customer's radio stations become initialized. So, you
need to record the customer's radio stations prior to service, and after service, set the customer's radio stations
into the audio.
Body Electrical System
Special Service Tools
Tool Name / Number
Illustration
RKE Battery Checker
09954-2P100
Description
Measuring the RKE battery
voltage
Body Electrical System
Specifications
Items
Specifications
Rated voltage
DC 5V
Load
Max. 1.5mA (When head lamp lighting)
Illuminations (LUX)
Body Electrical System
Component Location
100
1.89 ± 0.42(V)
200
3.55 ± 0.78(V)
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1. Auto light sensor
2. Head lamps
3. Lighting switch (Auto)
Body Electrical System
Circuit Diagram
4. Tail lamps
5. BCM (Body Control Module)
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Body Electrical System
Inspection
1. Operate the auto light switch, then check for continuity between terminals of multi-function switch connector.
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Body Electrical System
Inspection
In the state of IGN1 ON, when the multi function switch module detects auto light switch on, tail lamp relay output and head lamp low relay
output are controlled according to auto light sensor's input.
If IGN1 ON, The BCM monitors the range of this supply and raises up a failure as soon as the supply’s voltage is out of range. Then this
failure occurs and as long as this is present, the head lamp must be turned on without taking care about the sunlight level provided by the
sensor.
This is designed to prevent any head lamp cut off when the failure occurs during the night.
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the photo & auto light sensor (A) from crash pad upper side by using screw (-) driver.
3. Remove the auto light connector (B).
Installation
1. Reconnect the auto light connector.
2. Install the auto light sensor.
Body Electrical System
Specifications
AVN Head Unit
Item
Specification
Power supply
DC 14.4V Negative ground
Dark current
(Head unit only)
Frequency range /
Channel space
S/N
Dislpay
USA
ACC OFF & ADM OFF and then after 96 hours : Max. 0.5mA
ACC OFF & ADM OFF and then before 96 hours (average) : Max. 10mA
After ACC OFF & ADM OFF, Within 20 seconds (average) : Max. 70mA
CANADA
When ACC OFF & ADM OFF : Max. 0.5mA
FM
87.5 ~ 107.9 MHz / 200 kHz
AM
530 ~ 1,710 kHz / 9 kHz
FM
MIN 50 dB (20kHz LPF)
AM
MIN 45 dB (20kHz LPF)
Active area
176.4mm(H) × 99.36mm(V)
Resolution
800 × RGB × 480
GPS receiver
Frequency
1.57542 Ghz
Storage
Capacity
Flash Memory (NAND) : 16GB
Speaker
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Item
Input power (W or V)
Impedance (Ω)
Specification
Front
MAX 40W
Rear
MAX 40W
Tweeter
MAX 40W
Front
4.0 ± 0.6
Rear
4.0 ± 0.6
Tweeter
4.0 ± 0.6
Number of speaker
6
Body Electrical System
Components Location
1. AVN (A/V & Navigation head unit)
2. Tweeter speaker
5. Rear door speaker
6. Antenna feeder cable
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3. Roof antenna
4. Front door speaker
7. Back view camera
8. Feeder cable joint connector
Body Electrical System
Description
Limitations Of The Navigation system
GPS Signal Reception State
As the GPS satellite frequency is received/transmitted in straight lines, reception may not work if hiding devices are placed on or near the
GPS antenna or when traveling through the following locations.
• Tunnels
• Basement parking structures
• Underneath an overpass
• Roads within forested areas
• Areas near high rise buildings
• Roads within canyons
Vehicle Position Display
1. If multipass errors occur due to reflections from buildings or related causes, the current position mark on the navigation may differ from
the actual position of the vehicle.
2. The position of the vehicle on the navigation may be different from the actual position if the vehicle is under the occur, driving for a short
period of time will vehicle through map matching or GPS information (several minutes may be necessary in certain cases).
A. When driving on a Y-shaped road with a narrow angle, the current position may be displayed in the opposite direction.
B. If the vehicle is loaded onto a car transport vehicle, the current position mark may be stalled on the last position prior to loading.
C. When driving on a spiral-shaped road.
D. When driving in mountain regions with sharp turns or sudden brakes.
E. When entering a road after having been in an underground parking structure, building parking structure, or turnable with many
rotations.
F. When the tires have recently been replaced (Especially upon use of spare or studless tires)
G. If the battery terminal is removed.
H. When driving in city streets, the current position may be displayed on the opposite side or on an off-road position.
I. When changing the zoom level from the maximum zoom in level to a different zoom level, the current position mark may be displayed
on a different road.
J. When driving in heavy traffic with frequent go · stops in traffic or intersections.
K. When driving under slippery conditions, such as heavy sand, snow, etc.
L. When driving with the tire chain in place.
M. When using a tire with an incorrect size specification.
N. When the tire pressure for the 4 tires are different.
O. When the replacement tire is a worn or used tire (Especially studless tires having passed a 2nd seasons, etc.)
P. When driving near high-rise buildings
Q. If a roof carrier has been installed
R. When driving under high speeds or having calculated a long-distance route.
Route Guidance
Suitable route guidance may not occur caused by search conditions or the driving position.
• Guidance to go straight may be given while driving on a straight road.
• Guidance may not be given even when having turned at an intersection.
• There are certain intersections in which guidance may not occur.
• A route guidance signaling entrance into a no enter zone may occur (No enter zone, road under construction, etc.)
• Guidance may be given to a position removed from the actual destination if roads to reach the actual destination do not exist or are too
narrow.
• Faulty voice guidance may be given if the vehicle breaks from the designated route (ex : if a turn is made at an intersection while the
navigation provided guidance to go straight).
• Map Data may be missing or incorrect causing route guidance to not be given.
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Route Re-calculation
The following events may occur after conducting route recalculation.
• Guidance may be given to a position differing from the current position when turning at an intersection.
• Route recalculation may take a longer period of time when driving under high speeds.
• A route guidance signaling for a U-Turn in a No U-Turn location may occur.
• A route guidance signaling entrance into a no enter zone may occur (No enter zone, road under construction, etc).
• Guidance may be given to a position removed from the actual destination do not exist or are too narrow.
• Faulty voice guidance may be given if the vehicle breaks from the designated route (ex : if a turn is made at an intersection while the
navigation provided guidance to go straight)
Body Electrical System
Components
AVN (A/V & Navigation) Head Unit Connector
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Connector Pin Information
No.
Connector A
Connector B
Connector C
1
Rear left speaker (+)
MM CAN high
C CAN (-)
2
Front left speaker (+)
-
C CAN (+)
3
Front right speaker (+)
Parking
-
4
Rear right speaker (+)
Steering remocon
OBC wake up
5
-
-
6
-
MTS key
-
7
ALT L
AUX video
-
8
Illumination (+)
AUX right input
9
R position
AUX ground
-
10
Rear left speaker (-)
MIC (+)
-
11
Front left speaker (-)
Battery (+)
B CAN (+)
12
Front right speaker (-)
Battery (+)
B CAN (-)
13
Rear right speaker (-)
MM CAN low
-
14
Ignition 3
Auto light
Airbag
15
-
P position
-
16
Door unlock
Speed
-
17
Illumination (-)
Remocon ground
-
18
Remote antenna
ACC
Door open
19
AUX video ground
-
20
AUX DETECT
-
21
AUX left input
Ground
22
MIC (-)
Video ground
23
Ground
Camera video input
24
Ground
Camera battery (+)
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Body Electrical System
Removal
Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Disconnect the negative (-) battery terminal.
2. Remove the center fascia panel (A) from the crash pad.
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3. Disconnect the connectors (A) from the center fascia panel.
4. Remove the AVN head unit (A) after loosening the mounting screws.
5. Disconnect the connectors (A) from the AVN heat unit.
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Installation
1.
2.
3.
4.
Connect the AVN head unit connectors.
Install the AVN head unit.
Install the center fascia panel.
Connet the negative (-) battery terminal.
Make sure the AVN Head unit connectors are plugged in properly and the antenna cable is connected properly.
Inspection
1. Check the specified value of AVN head unit connectors in specified condition.
Connector A
No.
Name
Terminal Description
Condition
Specified Condition
A1
Rear left speaker (+)
Loudspeaker Rear Left+
Needed connection to the car
Analog output
A2
Front left speaker (+)
Loudspeaker Front Left+
Needed connection to the car
Analog output
A3
Front right speaker (+)
Loudspeaker Front Right+
Needed connection to the car
Analog output
A4
Rear right speaker (+)
Loudspeaker Rear Right+
Needed connection to the car
Analog output
A5
-
-
A6
-
-
A7
-
-
A8
Illumination (+)
Rheostat from vehicle +
A9
Detent
Detent
Needed connection to the car
A10
Rear left speaker (-)
Loudspeaker Rear Left-
Needed connection to the car
A11
Front left speaker (-)
Loudspeaker Front Left-
Needed connection to the car
Analog output
A12
Front right speaker (-)
Loudspeaker Front Right-
Needed connection to the car
Analog output
A13
Rear right speaker (-)
Loudspeaker Rear Right-
Needed connection to the car
Analog output
A14
-
-
A15
-
-
A16
-
-
A17
Illumination (-)
Rheostat from vehicle -
Needed connection to the car
Remote antenna
Remote Power supply for
Antenna
Acc on
A18
Needed connection to the car
Analog output
9V ~ 18V
Connector B
No.
Name
Terminal Description
Condition
Specified Condition
B1
MM CAN high
MM_CAN_HIGH
Needed connection to the car
Communication with
external amp
-
B2
-
-
-
B3
Parking
PARKING from vehicle
-
-
B4
Steering remocon
Steering Wheel Remote Control
Steering Wheel switch pushed
0.5V ~ 3V
B5
-
-
-
-
B6
MTS key
-
-
-
B7
AUX video
AUX Video
Needed connection to the MultiJack
-
B8
AUX right input
AUX Right Sound Signal
A waveform synchronized
with sound is output
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External Auxiliary device is Audio
playing
(At time of Aux jack use)
B9
AUX ground
AUX Reference Ground
Needed connection to the MultiJack
Below 1 ohm
B10
MIC (+)
Bluetooth MIC+
Input the Voice Signal via MIC
A waveform synchronized
with Voice data via MIC
B11
Battery (+)
Battery
Always
11 ~ 14 V
B12
Battery (+)
Battery
Always
11 ~ 14 V
MM CAN low
MM_CAN_LOW
Needed connection to the car
Communication with
external amp
B14
Auto light
AUTO-LIGHT from vehicle
-
-
B15
P position
P-POSITON from vehicle
-
Approx. 5V Level Pulse
Generation
Below 1 ohm
B13
B16
Speed
Speed Sensor Signal
Engine switch on(IGN), car is moved
slowly
B17
Remocon ground
Steering Wheel Remote Control
GND
Always
B18
ACC
Accessory
Engine switch on(ACC)
11 ~ 14 V
B19
AUX video ground
AUX Video GND
Always
Below 1 ohm
B20
AUX DETECT
AUX Signal Input Detect
Auxiliary device is inserted
0V(Low) → 5V(High)
A waveform synchronized
with sound is output
A waveform synchronized
with Voice data via MIC
B21
AUX left input
AUX Left Sound Signal
External Auxiliary device is Audio
playing
(At time of Aux jack use)
B22
MIC (-)
Bluetooth MIC-
Input the Voice Signal via MIC
B23
Ground
Ground
Always
Below 1 ohm
B24
Ground
Ground
Always
Below 1 ohm
Specified Condition
Connector C
No.
Name
Terminal Description
Condition
C1
C CAN (-)
CHASSIS_CAN_LOW
Needed connection to the car
-
C2
C CAN (+)
CHASSIS_CAN_HIGH
Needed connection to the car
-
C3
-
-
-
C4
-
-
-
-
C5
OBC wake up
-
-
-
C6
-
-
-
-
C7
-
-
-
-
C8
-
-
-
-
C9
-
-
-
-
C10
-
-
-
-
C11
B CAN (+)
BODY_CAN_HIGH
Needed connection to the car
-
C12
B CAN (-)
BODY_CAN_LOW
Needed connection to the car
-
C13
-
-
-
-
C14
Airbag
AIRBAG from vehicle
-
-
C15
-
-
-
-
C16
Navigation voice (-)
NAVI_VOICE-
Needed connection to the AMP
Analog Audio Output
C17
Navigation voice (+)
NAVI_VOICE+
Needed connection to the AMP
Analog Audio Output
C18
Door open
DOOR OPEN from vehicle
-
-
C19
-
-
-
-
C20
-
-
-
-
C21
Ground
Ground
Always
Below 1 ohm
C22
Video ground
CARMERA Video Ground
Needed connection to the CARMERA
Below 1 ohm
C23
Camera video input
CARMERA Video
Needed connection to the CARMERA
NA
C24
Camera battery (+)
CARMERA Video POWER
Needed connection to the CARMERA
5V~5.5V
USB Connector
No.
Name
Terminal Description
Condition
Specified Condition
1
USB VCC
USB / iPod power
USB/iPod device is inserted
4.9V ~ 5.1V
2
USB D (-)
USB D-
USB device is inserted
3.2V ~ 3.45
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3
USB D (+)
USB D+
USB device is inserted
3.2V ~ 3.45
4
USB ground
USB / iPod Ground
USB/iPod device is inserted
Below 1 ohm
Body Electrical System
Inspection
1. Troubleshooting for Speaker
(1) Basic inspection of speaker
Inspect the sound from speaker after verifying that the speaker mounting screws is removed and the wiring connector is connected
precisely to remove vibration transmitted from body trims and surrounding parts.
(2) Case Troubleshooting
No.
Case
Inspection/Remedy
1
1. Before replacing the speaker, inspect that the mounting screw is installed normally.
Trembling sound 2. After re-installing the speaker, verify that no trembling sound is heard.
3. When hearing a trembling sound again, replace the speaker with new one.
2
Noise
1. Check if the wiring connector is connected normally. If not, reconnect the wiring connector.
2. When a noise is heard on turning radio on, replace the speaker with new one.
Inspection of the wiring connection between the battery and the speaker
1. Before replacing the speaker, inspect the wiring and connections in the speaker circuit.
2. Check the supplying power to the speaker and the resistance, and then inspect the sound quality.
3
Poor working
3. If the speaker works poorly, replace it with new one.
When handling the speaker :
- Dropping or rough handling of the speaker can cause damage.
- Be careful not to spill water or oil on the speaker.
- Caution when dealing with speaker because the diaphragm is paper and can be easily torn by impact and external force.
- Electrical mishandling of speakers is not covered by manufacturers warranty.
Removal
Put on gloves to protect your hands.
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• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
Front Speaker
1. Remove the front door trim.
(Refer to Body - "Front Door Trim")
2. Remove the front speaker (A) after loosening the screws.
Rear Speaker
1. Remove the rear door trim.
(Refer to Body - "Rear Door Trim")
2. Remove the rear speaker(A) after loosening the screws.
Tweeter Speaker
1. Using a screwdriver or remover (A), remove the speaker grill (B) from the side air vent.
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2. Separate the tweeter speaker (A) after loosening the mounting screws.
3. Remove the tweeter speaker (B) after disconnecting the connector (A).
Installation
Front Speaker
1. Install the front speaker.
2. Install the front door trim.
Rear Speaker
1. Install the rear speaker.
2. Install the rear door trim.
Tweeter Speaker
1. Connect the connector.
2. Install the tweeter speaker and tweeter speaker grill.
Body Electrical System
Components
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1. Audio switch
2. Cruise switch
Body Electrical System
Circuit Diagram
3. Bluetooth hands free switch
4. Trip switch
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Body Electrical System
Inspection
1. Check for resistance or output voltage between terminals in each switch position.
[Audio]
Switch
Connector terminal
Resistance (±5%)
Output voltage
Seek up
2-4
430 Ω
0.4 V ± 0.22
Seek down
2-4
1.1 kΩ
1.0 V ± 0.22
Mode
2-4
2.11 kΩ
1.5 V ± 0.22
Mute
2-4
3.11 kΩ
2.0 V ± 0.22
Volume up
2-4
4.61 kΩ
2.5 V ± 0.22
Volume down
2-4
6.81 kΩ
3.0 V ± 0.22
[Cruise]
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Switch
Connector terminal
Resistance (±5%)
Output voltage
Cancel
2-4
180 Ω
0.8 V ± 0.17
Set
2-4
330 Ω
1.2 V ± 0.17
Resume
2-4
550 Ω
1.8 V ± 0.22
Cruise
2-4
880 Ω
2.3 V ± 0.22
Speed limit
2-4
2.54 kΩ
3.6 V ± 0.22
Switch
Connector terminal
Resistance (±5%)
Output voltage
Voice
2-4
10.71 kΩ
3.5 V ± 0.22
Call off
2-4
18.91 kΩ
4.0 V ± 0.22
Call
2-4
40.91 kΩ
4.5 V ± 0.22
Output voltage
[Voice + Bluetooth]
[Flex steer + Trip + Reset]
Switch
Connector terminal
Resistance (±5%)
Flex steer
2-4
180 Ω
0.8 V ± 0.17
Trip
2-4
330 Ω
1.2 V ± 0.17
Reset
2-4
550 Ω
1.8 V ± 0.22
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Removal
[Upper Steering Wheel Remote Control Switch]
1. Disconnect the negative (-) battery terminal.
2. Remove the driver airbag module.
(Refer to the RT group)
3. Remove the steering wheel.
(Refer to the ST group - "Steering column & shaft")
4. Loosen the mounting screws from the rear steering wheel cover.
5. Separate the upper steering wheel remote control switch (A) from the steering wheel.
[LH]
[RH]
6. Remove the upper steering wheel control switch (B) disconnecting the connector (A).
[LH]
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[RH]
[Lower Steering Wheel Remote Control Switch]
1. Disconnect the negative (-) battery terminal.
2. Remove the driver airbag module.
(Refer to the RT group)
3. Remove the steering wheel.
(Refer to the ST group - "Steering column & shaft")
4. Loosen the mounting screws from the rear steering wheel cover.
5. Separate the upper steering wheel remote control switch (A) from the steering wheel.
[LH]
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[RH]
6. Remove the upper steering wheel control switch (B) disconnecting the connector (A).
[LH]
[RH]
7. Separate the lower steering wheel control switch (A) loosening the mounting screws.
[LH]
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[RH]
8. Remove the lower steering wheel control switch (B) disconnecting the connector (A).
[LH]
[RH]
Installation
1. Install the remote control switch on the steering wheel.
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2. Install the steering wheel.
3. Reconnect the remote control switch connector and airbag connectors.
Make sure that the switch connector is plugged in properly.
4. Install the driver airbag module.
5. Connect the negative (-) battery terminal.
Body Electrical System
Circuit Diagram
Body Electrical System
Description
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The multimedia jack on the console upper cover is for customers who like to listen to external portable music players like the MP3, iPod and
etc., through the vehicle's sound system when it is linked to this jack. The customer has this added option.
In case of distortions from media connected to the AUX source, the audio unit may not be defective but the output level of the used media
does not match the specification of the AUX input.
Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the floor console upper cover.
(Refer to Body - "Floor Console Assembly")
3. Remove the multimedia jack (A).
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Installation
1. Install the multimedia jack.
2. Install the floor console upper cover.
3. Connect the negative (-) battery terminal.
Body Electrical System
Components
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Disconnect the roof antenna connectors (A).
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3. Disconnect the roof antenna power connector (A).
4. Remove the roof antenna after loosening a nut (A).
Installation
1. Connect the roof antenna connectors.
2. Install the rear roof trim.
3. Connect the negative (-) battery terminal.
- Make sure that the cables and connectors are plugged in properly.
- Check the AVN system.
Body Electrical System
Troubleshooting Guide
Troubleshooting (Step type)
Symptom
Pressing power switch does not turn on system
Panel switch does not function
Suspected area
Repairment
Radio receiver power source circuit
R-1
LCD module
R-1
Steering pad switch circuit
R-3
AVN head unit front PCB ass'y
R-1
Radio receiver power source circuit
R-1
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Radio receiver power source circuit
R-1
Check the wiring between speakers and AVN H/U
R-6
Noise occurs
Proceed to "noise occurs"
R-5
Radio broadcast cannot be received (poor
reception)
Proceed to "radio broadcast cannot be received"
(poor reception)
R-4
No sound can be heard from speakers
Illumnination for radio receiver does not come on Illumination circuit
within light control switch on
Radio receiver power source circuit
Display does not dim with light control switch
turned on
Power does not turn off
Bluetooth voice recognition fault
USB I/F error
iPod I/F error
AUX connection error
R-6
R-1
Illumination circuit
R-6
AVN H/U
R-1
AVN H/U
R-1
MIC input
R-7
AVN head unit
R-1
USB device fault
R-8
Check the multimedia connector
R-8
AVN H/U
R-1
Check the multimedia connector
R-8
AVN H/U
R-1
Check the multimedia connector
R-8
R-1 : Replace the AVN head unit
1. Check the same problem after replacing the AVN H/U.
OK
▶ If AVN is normal operating, replace the AVN H/U.
NG
▶ Check the vehicle wiring. (Refer to removal procedure, R-2)
R-2 : Check the power connection of AVN H/U
1. Remove the AVN H/U.
2. Check the specified condition of terminal.
OK
NG
Tester Connection
Condition
CON-B11/B12 ↔ GND (B+)
Always
9 ~ 16 V
CON-B18 ↔ GND (ACC)
Always
9 ~ 16 V
CON-B23 ↔ GND
Always
Below 1Ω
CON-B24 ↔ GND
Always
Below 1Ω
▶ Check again after repairing or replacing the cable harness or connector.
Specified Condition
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R-3 : Check the steering wheel remote control
1. Check the steering wheel remote control connector specification (Refer to “Audio remote control inspection”)
OK
▶ Replace the AVN H/U
NG
▶ Replace the steering wheel remote control switch
R-4 : Radio broadcast cannot be received (Bad reception)
1. Check the radio broadcast reception after replacing the AVN H/U
OK
▶ If AVN is normal operating, replace the AVN H/U
NG
▶ Go to step 2
2. Check the antenna jack
OK
▶ Check again the radio broadcast reception after connecting the antenna jack
NG
▶ Go to step 3
3. Check the antenna amp input voltage (Refer to “Antenna –Glass antenna circuit inspection”)
OK
▶ Check the antenna amp input voltage (Refer to “Antenna –Antenna cable”)
NG
▶ Go to step 4
4. Check the feeder cable connection (Refer to “Antenna –Antenna cable”)
OK
▶ Check again after repairing or replacing the antenna feeder cable.
NG
▶ Go to step 5
5. Check and repair the roof antenna.
R-5 : Check that speakers are installed tightly
OK
▶ Install the speakers tightly
NG
▶ Install the speakers tightly
1. Noise source description
Condition in Which Noise Occurs
Noise Type
Depressing accelerator pedal increases noise, and stopping engine stops noise
immediately
Generator nosie
When A/C or heater is operating
Blower motor noise
• When rapidly accelerating on unpaved road
• When engine switch is turned on (IG)
Fuel pump noise
• When horn switch is pressed and released
• When horn switch is pressed and held down
Horn noise
Running engine causes soft noise, and stopping engine stops noise immediately Ignition noise
Noise occurs synchronously with turn signal flash
Flasher noise
Noise occurs during window washer operation
Washer noise
Running engine causes noise, but stopping engine does not stop noise
Engine coolant temperature sensor noise
When wiper is operating
Wiper noise
When brake pedal is depressed
Stop light switch noise
Other
Static electricity on vehicle
R-6 : Check again after replacing the AVN H/U
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OK
▶ Removed the AVN H/U
NG
▶ Go to step 1
1. Check the input signal of illumination (+)
Tester Connection
Condition
Specificed Condition
CON-A8 ↔ GND
Always
9~16 V
OK
▶ Check the vehicle wiring
NG
▶ Go to step2
2. Check the illumination (-) input signal using the oscilloscope
Tester Connection
Condition
Specificed Condition
CON-A17 ↔ GND
Always
Check the PWM waveform
OK
▶ Check the vehicle wiring and cluster PWM output
NG
▶ Go to step3
3. Check the vehicle illumination control unit
R-7 : Check the microphone input condition
Tester Connection
Condition
Specificed Condition
CON-B10 ↔ MIC (+)
Always
Below 1Ω
CON-B22 ↔ MIC (-)
Always
Below 1Ω
CON-B22 ↔ GND
Always
Open
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OK
▶ Check the vehicle wiring and microphone
NG
▶ Go to step1
1. Test again after replacing the microphone
R-8 : Test after replacing the AVN H/U
1. Test after replacing the multimedia jack
OK
▶ Replace the multimedia jack
NG
▶ Go to step 2
2. Check the vehicle USB cable.
OK
▶ Replace the vehicle USB cable
NG
▶ Go to step 3
3. Check the multimedia jack connector
Tester Connection
Condition
Specificed Condition
AVN H/U CON-B8 ↔ Multimedia jack CON-C2
Always
Below 1Ω
AVN H/U CON-B21 ↔ Multimedia jack CON-C1
Always
Below 1Ω
AVN H/U CON-B20 ↔ Multimedia jack CON-C3
Always
Below 1Ω
AVN H/U CON-B9 ↔ Multimedia jack CON-C7
Always
Below 1Ω
Troubleshooting (Flow chart type)
There are six areas where a problem can occur
: the power system, the LCD/LED system, the sound system, the radio system, the USB/iPod/AUX system, and the bluetooth system.
Troubleshooting enables you to confine the problem to a particular area.
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Body Electrical System
Component Location
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1. Back view camera
Body Electrical System
Circuit Diagram
2. AVN head unit
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Body Electrical System
Description
Back view camera will activate when the backup light is ON with the ignition switch ON and the shift lever in the R position.
This system is a supplemental system that shows behind the vehicle through the monitor while backing-up.
This system is a supplementary function only. It is the responsibility of the driver or always check the inside/ outside rearview mirror and
the area behind the vehicle before and while backing up because there is a dead zone that can't see through the camera.
Body Electrical System
Removal
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1. Remove the tailgate trim.
(Refer to Body - "Tailgate Trim")
2. Remove the tailgate back panel.
(Refer to Body - "Tailgate Back Panel")
3. Remove the back view camera (A) after loosening the mounting screws.
Installation
1. Install the back view camera.
2. Install the tailgate back panel and tailgate trim.
Body Electrical System
Specifications
Items
Specifications
Rated voltage
DC 12V
Operating voltage
DC 9 ~ 16V
Operating temperature
-30°C ~ 80°C (-4°F ~ 176°F)
Dark current
BCM & Receiver : Max. 4 mA
BCM : Max. 3 mA
Body Electrical System
Components
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Connector Pin Information
No.
Connector A (24 pin)
Connector B (20 pin)
Connector C (26 pin)
Connector D (16 pin)
1
Battery (+)
LIN (PAS)
Washer motor power
-
IGN 1
Fuel filler (Charge door)
actuator relay
Front washer motor
-
3
IGN 2
LS CAN high
-
-
4
Brake switch
LS CAN low
Mirror unfold relay
Mirror unfold switch
5
Wiper mist switch
Mood lamp unlock state
DRL lamp LH
Mirror fold switch
6
Crash unlock input (PWM)
Horn relay
DRL lamp RH
-
7
-
-
Room lamp
-
8
Fuel filler (Charge door) open
switch
HS CAN low
-
-
2
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9
Wiper washer switch
HS CAN high
-
Auto ligth switch
10
Wiper INT switch
Ground (Auot light)
-
Defogger switch
11
Wiper low switch
Auto light signal
-
-
12
Rear washer switch
Auto light power
Wiper low relay
Head lamp high switch
13
ACC
Safety power window enable
high
-
Head lamp low switch
14
Wiper high switch
-
DRL lamp power
-
15
Front fog lamp switch
ATM solenoid
Rear washer motor
-
16
Rear wiper switch
-
Mirror fold relay
-
17
Rear INT switch
Fuel filler (Charge door) lamp
MTS Tx
18
-
-
-
19
-
-
Head lamp low signal
20
-
Ground (Power)
21
Tail switch
AV tail
Wiper high relay
22
Wiper INT volume
-
23
LIN (Intelligent Battery Sensor)
-
24
Ground (Signal)
-
25
-
26
Ground (Power)
Body Electrical System
Description
BCM CAN Communication
Function
Function
Timer
Defroster
Safety Power Window
Tailgate
Description
When IGN ON, Rear Heater Control Function
According to the position of key, Power Window Output Control
Tailgate Open and Open Prohibition Control Function
Panic Alarm
Using the RKE My Vehicle Searching Function
Driving
ATM Solenoid
Shift Lever Automatic Release Protection Control Function
Interior Lamp
Room Lamp
Room Lamp Control Function
Exterior Lamp
Tail Lamp
Interior Illumination Control and Tail Lamp Control Function
H/Lamp Low & High
Head Lamp Low/High/Passing Control Function
Front Fog Lamp
Front Fog Lamp Control Function
AV Tail
Autolight Interlock Illumination Control Fucntion
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Wiper Washer
Warning
Door
DRL
When the Key turns IGN ON in the daytime. Dedicated DRL Illumination
Control Function
Wiper Low/High
Front Wiepr Low/High Control Function
Wiper MIST
Front Wiper MIST Control Function
Wiper Washer (FRONT, REAR)
When Front/Rear Washer switchs ON, Washer Motor Output Function
Wiper INT
According to Intermittent Volume input signal, Front Wiper Control Function
Rear Low
Rear Wiper Low Control Function
Rear INT
Rear INT Wiper Control Function
DRV SBR
Driver Seat Belt Reminder Warning Function
Key Operated Warning
When the key turns ACC ON and Driver Door Open, Warning Function
Parking Brake Warning
When the Parking brake switchs ON and vehicle drives, Warning Function
SMK System Warning
SMK Warning Function
Key Teaching Warning
When the RKE Teaching is completed, Warning Function
CRASH
When vehicle crashes, All Door Unlock Control Function
Auto Door Lock/Unlock
According th USM setting, Door Lock/Unlock Automatic Control Function
Out side Mirror
Body Electrical System
Circuit Diagram
Out Side Mirror Folding / Unfolding Output Function
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the audio/ AVN head unit assembly.
(Refer to Body Electrical System - "Audio Unit")
(Refer to Body Electrical System - "AVN Head Unit")
3. Remove the glove box housing assembly.
(Refer to Body - "Glove Box Housing")
4. Separate the wiring fixed clip (A) on the BCM bracket.
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5. Loosen the mounting nuts from the BCM unit.
6. Disconnect the connectors from the BCM (in the order as below)
(1) Disconnect the connectors (A) from the direction of removing the Audio/ AVN head unit.
(2) Disconnect the connectors (A) from the direction of removing the glove box housing.
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Installation
1. Connect the connectors and install the BCM.
2. Install the glove box housing and audio/AVN head unit.
3. Connect the negative (-) battery teriminal.
BCM Diagnosis With GDS
1. The body control module can diagnose by using the GDS more quickly.
The BCM communicates with the GDS and then reads the input/output value and drives the actuator.
2. To diagnose the BCM function, select the menu of model and body control module.
3. Select "Input/output monitoring", if you will check current data of body network system. It provides input/output status of each module.
A. BCM service data, CLU service data, SJB service data
4. If you will check each module data operation forcefully, select "Actuation test".
5. If you want to change user option, select “user option”.
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Body Electrical System
Component Location
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1. Start Stop Button(SSB)
2. FOB key
3. Smart key unit
4. Interior antenna 1
Body Electrical System
Circuit Diagram
5. Interior antenna 2
6. Bumper antenna
7. Door handle & door antenna
8. Tailgate open switch
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Body Electrical System
Description
System Overview
The System offers the following features:
- Human machine interface through a 1-stage button, for terminal switching and engine start.
- Control of external relays for ACC / IGN1 / IGN2 terminal switching and STARTER, without use of mechanical ignition switch.
- Indication of vehicle status through LCD or explicit messages on display.
- Immobilizer function by LF transponder communication between fob and start/stop button.
- Redundant architecture for high system dependability .
- Interface with Low Speed CAN vehicle communication network.
- Interface with LIN vehicle communication network depending on platform .
The RKE and SMART KEY functions are not considered part of this Button Engine Start system and are specified in separated system.
System Main Function
- Switching of ACC / IGN1 / IGN2 terminals.
-
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Control of the STARTER relay BAT line (high side) based on communication with EMS ECU.
- Management of the Immobilizer function.
- Management of BES warning function.
Button Engine Start System
The Button Start System allows the driver to operate the vehicle by simply pressing a button (called as SSB) instead of using a standard
mechanical key.
When the driver pushes the SSB, upon authentication of the smart key, if the brake signal and the shift signal (P) have been received
correctly, the SMK System will proceed with the unlocking of the steering column, the control of the terminal, and enable READY mode.
The driver can release the SSB as soon as this sequence initiated. After positive response from immobilizer interrogation, the system will
communicate with the VCU and turns on the READY lamp and puts the vehicle to "standby" for drive.
The driver will be able to shut-off EV by a short push on the SSB if the vehicle is already in standstill and shift position on either P or N.
Emergency engine stop will be possible by a long press of the SSB or 3 consecutive presses in case the vehicle is in READY mode.
If the conditions for READY mode are not received correctly while pushing the SSB is detected and a valid fob authenticated, the system will
unlock the steering column and switch the terminals to IGN. Another push on the SSB will be necessary to go into READY mode.
In case of a vehicle equipped with SMART KEY system, fob authentication will not require any action from the driver. For limp home start or
in case of vehicle without SMART KEY, the driver will have to push the start / stop button.
• Control Ignition and engine ON/OFF by Sending signal to IPM.
• Display status by LED Lamp ON/OFF. (Redish orange or Amber)
Indicator ON/OFF Condition At Ignition Button OFF Condition
No.
Character lamp
Conditions
1
Indicator Lamp ON
Door open, Tail lamp ON, ACC, IG ON
2
Indicator Lamp 30sec ON → Lamp OFF
Door close, Tail lamp OFF, IG OFF
3
Indicator Lamp OFF
Remote LOCK, Passive LOCK
4
Rheostat at tail lamp ON (Illumination lamp)
Indicator ON/OFF Condition According To Ignition
No.
Ignition conditions
1
IG OFF
Start Button LED status
LED OFF
2
IG ACC
Amber color LED ON
3
IG ON (Engine OFF)
Redish orange color LED ON
4
Cranking
Maintain LED status before cranking
5
Engine running
LED OFF
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Wireless Communication
Electromagnetic waves are used to exchange information between the vehicle and the FOB. Two types of RKE Key can supplement the
BES system:
- Non-smart key RKE
- SMART KEY FOB
Currently the BES system comprises with SMART KEY FOB always.
The transmitter, receiver and antennas required for the communication between the fob and the vehicle will differ depending on
functionalities and regional areas.
The RKE and SMART KEY functions are in separated documents. Refer to Smart key system for more detailed information about SMART
KEY function.
Smart Key
The SMK manages all function related to:
• "Start Stop Button (SSB) monitoring",
• "Immobilizer communication" (with Vehicle Control Unit for immobilizer release),
• "ESCL control",
• "Authentication server" (Validity of Transponder and in case of Smart Key option Passive Fob authentication ),
• "System consistency monitoring",
• "System diagnosis",
• Control of display message / warning buzzer .
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The unit behaves as Master role in the whole system.
In case of SMART KEY application, for example “Passive Access”, “Passive Locking” and “Passive Authorization are integrated for
ESCL/Terminal switching Operations”.
It collects information about vehicle status from other modules (vehicle speed, alarm status, driver door open...), read the inputs (e.g. SSB,
Lock Button and PARK position Switch), controls the outputs (e.g. exterior and interior antennas), and communicates with others devices via
the CAN network as well as a single line interfaces.
The diagnosis and learning of the components of the BES System are also handled by the SMK.
Transponder
Terminal And Starter Relays
Relays will be used to switch the terminals ACC / IGN1 / IGN2. Those normally-open relays will be driven by the SMK unit and located either
in the passenger or engine compartment depending on the vehicle architecture.
Only one relay coil is connected to the terminal outputs of the SMK unit.
Those relays should integrate a resistor connected in parallel to the coil in order to reduce the transients during commutation.
Start/Stop Button(SSB)
A single stage push button is used for the driver to operate the vehicle. Pressing this button allows:
• To activate the power modes ‘Off’, ’Accessory’, ‘Ignition’ and 'Start' by switching the corresponding terminals
• To go into READY mode (standby)
• To shut-off EV vehicle
The contact will be insured by a micro-switch and a backlighting is provided to highlight the marking of the button whenever necessary.
Two (2) LED colors are located in the center of the button to display of the status of the system. Another illumination LED is also integrated
into the SSB for the lighting of the "Engine Start/Stop" characters.
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BES System State Chart
System STATES in LEARNT MODE
In learnt mode, the BES System can be set in 6 different sates, depending on the status of the terminals and Engine status:
System State
Terminal Status
1. OFF - Locked
OFF
Engine status
Stopped
2. OFF - Unlocked
OFF
Stopped
3. ACC
ACC
Stopped
4. IGN
IGN1, IGN2, ACC
Stopped
5. Start
IGN1, Start
Cranking
6. IGN - Engine
IGN1, IGN2, ACC
Running
(means "self-running")
Referring to the terminals, the system states described in the table above are same as those one found in a system based on a mechanical
ignition switch. The one of distinction with Mechanical-Ignition-Switch based system is that the BES system allows specific transition from
[OFF] to [START] without going through [ACC] and [IGN] states.
System STATES IN VIRGIN MODE
The BES System can be set in 5 different states (OFF LOCKED is not available in virgin mode), depending on the status of the terminals
and Engine status:
System State
Terminal Status
Engine status
1. OFF - UNLOCKED
OFF
Stopped
2. ACC
ACC
Stopped
3. IGN
IGN1, IGN2, ACC
Stopped
4. Start
IGN1, START with special pattern of
activation see Chap 6.2.1 for details
Cranking
5. IGN - Engine
IGN1, IGN2, ACC
Running
(means "self-running")
Referring to the terminals, the system states described in the table above are same as those one found in a system based on a mechanical
ignition switch. The one of distinction with Mechanical-Ignition-Switch based system is that the BES system allows specific transition from
[OFF] to [START] without going through [ACC] and [IGN] states.
Body Electrical System
Component
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the gear knob (A) from the console upper cover after pulling out it to upward.
3. Using the screw driver or remover, remove the console upper cover (A).
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4. Disconnect the indicator connector (A) and start/stop switch connector (B).
5. Disconnect the multimedia jack connector (A).
6. Diconnect the gear lever lamp connector (A) and wiring.
7. Remove the start/stop button (A) after loosening the mounting screws.
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Installation
1. Install the start/stop button.
2. Install the console upper cover and gear knob.
3. Connect the negative (-) battery termninal.
Body Electrical System
Components Location
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1. Charge door opener actuator switch
2. Charge door opener actuator
Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
3. Remove the charge door opener cover assembly.
(Refer to Body - "Charge Door Opener Cover")
4. Remove the charge door opener actuator cabel (A).
3. Charge door opener cover
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5. Remove the charge door opener actuator © after loosening the mounting bolts (A) and screw (B).
Installation
1.
2.
3.
4.
Install the charge door opener actuator and cable.
Install the charge door opener cover assembly on the front bumper cover.
Install the front bumper cover.
Connect the negative (-) battery terminal.
Inspection
1. Remove the connector from the charge door opener actuator.
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2. Connect battery positive (+) and negative (-) cables to terminals 1 and 2 respectively.
3. Check that the motor operates normally. Replace the motor if it operates abnormally.
Body Electrical System
Components
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the crash pad lower switch assembly (A) by pushing it.
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4. Disconnect the connector (A) from the crash pad lower switch assembly.
5. Remove the crash pad lower switch (A).
6. If it is necessary to check the switch, check for continuity and measure the resistance between terminals.
Installation
1. Install the crash pad lower switch.
2. Install the crash pad lower panedl after connecting the connector.
3. Connect the negative (-) battery terminal.
Body Electrical System
Components
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Body Electrical System
Description
The Electro Chromatic inside rear view Mirror (ECM) is intended dim the reflecting light in the rear view mirror. The forward facing sensor
detects brightness of the surroundings, while the rearward looking sensor is for the light from the rear. The strength of the light in the rear
sensor is used by the mirror to adjust the shading. It ranges from 7 to 85%. When the reverse gear is engaged, it stops functioning.
1. The forward facing sensor sees if the brightness of the surroundings is low enough for the mirror to operate its function.
2. The rearward looking sensor detects glaring of the reflecting light from a vehicle behind.
3. The ECM is darkened to the level as determined by the rearward looking sensor. When the glaring is no longer detected, the mirror stops
functioning.
(1. LED indicator , 2. ON/OFF Switch , 3. Rearward looking sensor , 4. Forward looking sensor )
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Automatic-dimming Function
To protect your vision during nighttime driving, your mirror will automatically dim upon detecting glare from the vehicles traveling behind you.
The auto-dimming function can be controlled by the Dimming ON/OFF Button :
1. Pressing and holding the Feature Control button for more than 3 but less than 6 seconds turns the auto-dimming function OFF which is
indicated by the green Status Indicator LED turning off.
2. Pressing and holding the Feature Control button again for more than 3 but less than 6 seconds turns the auto-dimming function ON
which is indicated by the green Status Indicator LED turning on.
The mirror defaults to the "ON" position each time the vehicle is started.
Body Electrical System
Inspection
Check it by the procedure below to see if the function of the ECM is normal.
1. Turn the ignition key to the "ON" position.
2. Cover the forward facing sensor.
3. Head a light to the rearward looking sensor.
4. The ECM should be darkened as soon as the rearward looking sensor detects the light.
If this test is performed in daytime, the ECM may be darkened as soon as the forward facing sensor is covered.
5. When the reverse gear is engaged, the ECM should not be darkened.
When heading lights to both the forward facing and rearward looking sensors, the ECM should not be darkened.
Removal
1. Remove the mirror wiring cover (A).
2. Disconnect the ECM mirror connector (B).
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3. Loosen the mounting screw (B).
4. Push the ECM mirror base up to remove the ECM mirror assembly (A).
Make sure not to damage the mounting bracket when removing the mirror.
Installation
1. Install the mirror making sure the mounting bracket not to be damaged.
2. Install the mirror wiring cover after reconnecting the connector and tightening the screw.
• Make sure the connector is connected properly.
• Replace any damaged clips.
Body Electrical System
Component Location
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1. Power outlet relay
2. Cooling fan relay 1
3. Defroster relay
4. Cooling fan relay 2
5. EMS Box
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Body Electrical System
Component Location
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Body Electrical System
Inspection
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1. Disconnect the negative (-) battery terminal.
2. Pull out the relay from the engine compartment relay box.
Power Relay (Type A)
- Do not use pliers.
- Pliers will damage the relays, which could cause the engine to stall or not start.
- Carefully remove the relay using the relay puller.
Check for continuity between the terminals.
A : Power outlet relay
B : Cooling fan relay 1
C : Defroster relay
1. There should be continuity between the No.30 and No.87 terminals when power and ground are connected to the No.85 and No.86
terminals.
2. There should be no continuity between the No.30 and No.87 terminals when power is disconnected.
Power Relay (Type C)
Check for continuity between the terminals.
A : Cooling fan relay 2
1. There should be continuity between the No.30 and No.87 terminals when power and ground are connected to the No.85 and No.86
terminals.
2. There should be no continuity between the No.30 and No.87 terminals when power is disconnected.
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Replacement of EMS box
1. Disconnect the negative (-) battery terminal.
2. Loosen the mounting nut (A) and bolt (B).
3. Reomve the engine room fuse & relay box from the hole (A).
4. Separate the engine room upper box (A) and lower cover (B).
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5. Remove the wire cover (A) on the engine room lower box.
6. Disconnect the connectors (A) from the EMS box.
Fuse
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew first and completely
eliminate the problem before installing a new fuse.
Multi Fuse
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- Multi fuse (A) is needed to replace in the mass when it damaged only one fuse.
- When replace the multi fuse, refer to the "Engine compartment - component location" diagram exactly.
- Use the multi fuse capacities for each circuit correctly.
Body Electrical System
Component Location
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Body Electrical System
Description
Smart Junction Box(SJB)
1. General function : Interior Junction Box + some functions of BCM
It controls loads with CAN communication and IPS.
2. Main function
A. Low speed CAN communication(100 kbps)
B. Self diagnostics(Lamp open/short)
C. Fail safe(When MCU/CAN is fail, Head lamp / Tail lamp directly drive)
D. Protection of bulb over-voltage(PWM function)
E. Cut of Over-load and Short : PCL(Program Current Limit)
Auto Cut System Of Dark Current
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1. Description : It cuts automatically power to be provided with load for reducing useless dark current according to vehicle state.
2. SJB had 3 modes, "Normal Mode", "Sleep Mode", "Power Off Mode". Auto cut of dark current practice in "Sleep Mode".
A. "Sleep" condition : IG OFF, constant input switch, CAN network doesn't activate.
B. "Sleep" resolutive condition : Any switch inputs, CAN network activates, KEY ON, IGN ON
C. "Power OFF" condition : The setting time of timer which is used by cutting a load power expires.
D. "Normal Mode" : SJB function normally activates.
E. "Sleep Mode" : It is low power mode and activates for reducing electricity consumption of SJB or IPM. Auto cut of dark current
function activates.
F. "Power OFF Mode" : Power of MCU and circumferential circuit is cut for minimizing electricity consumption. Operation stops.
3. The explanation - The auto cut of dark current
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Before delivering to customer
Fuse switch OFF
•All door close & RKE door lock or Constant switch state
(Auto cut of dark current scenario starts.)
-After "sleep" state is for 20 min.
-SJB power down(SJB dark current : 200 μA) and cutting power of Lamp/Body Load/Wake up
After delivering to customer
•All door close & Constant switch state : C_BAState=OFF
(Auto cut of dark current scenario starts.)
-After "sleep" state is for 20 min.
-SJB power down(SJB dark current : 200 μA) and cutting power of Lamp Load
•In case RKE door lock : C_BAState=ON & Trunk SW=CLOSE
(Auto cut of dark current scenario starts.)
-After "Sleep" state 35s~65s (Waiting time of other unit : 30~60s + SJB sleep counts 5s)
-SJB Powerdown(SJB dark current : 200 μA) and cutting power of Lamp Load
Fuse switch ON
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4. Problem when mode switch setting is wrong
: If a fuse switch is set to OFF(Before delivering to customer) by a customer or technician and auto cut function of dark current activates,
below problems may happen.
Symptom
•Door lock/unlock, trunk open don't activate by RKE.
(Wakeup of each module don't activate.)
•Digital clock is reset.(Memory is reset.)
•Setting value of audio(Volume, Frequency setting) is reset.
(Memory is reset.)
Related part
BCM
Digital clock
Audio
*If fuse switch OFF(before delivering to customer) is set, power of BCM, Digital clock and audio is shut off.
Body Electrical System
Fuse Inspection
1. Be sure there is no play in the fuse holders, and that the fuses are held securely.
2. Are the fuse capacities for each circuit correct?
3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew first and completely
eliminate the problem before installing a new fuse.
Inspection
1. The SJB can be diagnosed by using the GDS. The SJB communicates with the GDS which then displays inputs and outputs along with
codes.
2. To diagnose the SJB function, select the vehicle model, BCM and SJB.
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3. To consult the present input/out value of SJB, "Current DATA". It provides information of SJB input/output conditions.
4. To perform functional test on SJB outputs, select "Actuation Test"
Removal
Passenger Compartment Junction Box (SJB)
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1. Disconnect the negative(-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Disconnect the connectors from the fuse side of the smart junction box.
4. Remove the smart junction box (A) after loosening the mounting nuts and bolt.
5. Disconnect the connectors from the back side of the smart junction box.
Installation
1. Install the smart junction box.
2. Install the crash pad lower panel.
3. Check that all system operates normally.
Body Electrical System
Component
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Body Electrical System
Description
The ICM relay is united with (outside mirror fold/unfold relay, front deicer relay, rear fog lamp relay) which installed inside the lower crash
pad.
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Body Electrical System
Inspection
Normal Charge Port Relay
Check for continuity between the terminals.
1. There should be continuity between the No.20 and No.10 terminals when power and ground are connected to the No.10 and No.9 in the
ICM-A.
Folding Motor Relay
Check for continuity between the terminals.
1. There should be continuity between the No.16 and No.17 terminals when power and ground are connected to the No.4 and No.8 in the
ICM-A.
Unfolding Motor Relay
Check for continuity between the terminals.
1. There should be continuity between the No.15 and No.17 terminals when power and ground are connected to the No.6 and No.8 in the
ICM-A.
Body Electrical System
Components
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1. Hands free call switch
2. Mic
3. Front left speaker
4. Front right speaker
5. AVN head unit (hands free control)
※ There is no hands free jack. This system supports Bluetooth (wireless system).
Body Electrical System
Function
Audio Bluetooth System
General Features
• This audio system supports Bluetooth® hands-free and stereo-headset features.
- HANDS-FREE feature : Making or receiving calls wirelessly.
- STEREO-HEADSET feature : Playing music from cellular phones (that supports A2DP feature) wirelessly.
• The phone must be paired to the system before using Bluetooth® features.
• Only one selected (connected) cellular phone can be used with the system at a time.
• Some phones are not fully compatible with this system.
Body Electrical System
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Circuit Diagram
Body Electrical System
Inspection
1. Check for resistance between terminals in each switch position.
[Voice + Bluetooth]
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[Voice + Bluetooth]
Switch
Connector terminal
Resistance
(±5%)
Output voltage
(± 0.22)
Voice
2-4
10.71 kΩ
3.5 V ± 0.22
Call off
2-4
18.91 kΩ
4.0 V ± 0.22
Call
2-4
40.91 kΩ
4.5 V ± 0.22
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the driver airbag module.
(Refer to the RT group)
3. Remove the steering wheel.
(Refer to the ST group - "Steering column & shaft")
4. Loosen the mounting screws from the rear steering wheel cover.
5. Separate the upper steering wheel remote control switch (A) from the steering wheel.
[LH]
[RH]
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6. Remove the upper steering wheel control switch (B) disconnecting the connector (A).
[LH]
[RH]
7. Separate the lower steering wheel control switch (A) loosening the mounting screws.
[LH]
8. Remove the lower steering wheel control switch (B) disconnecting the connector (A).
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[LH]
Installation
1. Install the remote control switch on the steering wheel.
2. Install the steering wheel.
3. Reconnect the remote control switch connector and airbag connectors.
Make sure that the switch connector is plugged in properly.
4. Install the driver airbag module.
5. Connect the negative (-) battery terminal.
Body Electrical System
Inspection
1. Disconnect the negative (-) battery terminal.
2. Remove the overhead console lamp.
(Refer to Body Electrical - "Overhead Console Lamp")
3. Remove the hands free mic (A) from the overhead console lamp loosening the mounting screws.
No.
Description
1
Mic (+)
2
Mic (-)
4. Check the continuity of mic between terminals.
Body Electrical System
Troubleshooting
Problem
Not pairing
Possible cause
Solution
Bluetooth device of Car is not discoverable mode
Enter Bluetooth pairing (searching) mode
User’s phone is Bluetooth off mode
User’s phone set Bluetooth on
Making an attempt pairing others bluetooth system
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Check Bluetooth device name and address (12 word) to
attempt paring
Ex) 000B24FFF123
Pass key error
Input the passkey displayed on the audio screen into
the phone.
5 phones have already been registered.
Delete paired phone list
Bluetooth system cannot communicate with the phone. Refer to IOP sheet
※IOP : Inter-operability
Not connection
User’s phone or Bluetooth device of Car does not
register
Bluetooth device to connect
Retry pairing
Bluetooth system cannot communicate with the phone. Waiting 1minute then Retry connection or phone power
off/on.
Refer to IOP sheet
Not redial
User phone system issue
Push the 2 times Send button
Not accept call
User phone system issue
Refer to IOP sheet
Not dialing
User’s phone playing other menu (internet, mp3, game, Stop other menu then set normal mode
etc..)
Bluetooth system cannot communicate with the phone Refer to IOP sheet
Body Electrical System
Component Location
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1. Horn switch
2. Horn relay (EMS box)
3. Horn
4. Clock spring
Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove engine room under cover.
(Refer to Motor System - "Under Cover")
3. Remove the horn (A) after disconnecting the mounting bolt and connector.
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Installation
1. Install the horns after connecting the horn connectors.
2. Install the engine room under cover.
Inspection
Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
The horn should make a sound. If the horn fails to make a sound, replace it.
Body Electrical System
Component Location
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1. Cluster assembly
2. Seat belt switch
3. Brake fluid level warning switch
4. Parking brake switch
Body Electrical System
Components
5. Door switch
6. Tailgate switch
7. Wheel speed sensor
8. ABS ECU
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Connector Pin Information
No.
Description
No.
Description
1
2
Ground signal 3 (Power ground)
21
Trip switch (-) input
Illumination output (-)
22
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Trip switch 1 (+) input
(Trip button)
3
Rheostat switch down input
23
Trip switch 2 (+) input
(Cruise button)
-
4
Rheostat switch up input
24
5
Detent output (+)
25
-
6
P output (+) (A/T)
26
Low washer level input (-)
7
R output (+) (A/T)
27
-
8
N output (+) (A/T)
28
Heated wheel indicator input
9
D output (+) (A/T)
29
M CAN low
10
S output (+) (A/T)
30
M CAN high
11
ALT L output
31
-
12
-
32
C CAN high
C CAN low
13
-
33
14
-
34
-
15
Airbag (+) input
35
-
16
-
36
-
17
-
37
Ground signal 1
18
Speed output (4P output)
38
-
19
IGN 3
39
IGN 1
20
Tail lamp input
(Illumination (+))
40
Battery (+)
Body Electrical System
Circuit Diagram
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Body Electrical System
Description
Mian Features
1. Power and charge guage
(1) It displays the degree of economic driving by identifying the status of a driver's operation, depending on a vehicle's driving conditions
(e.g., required power, system efficiency and charging).
(2) It leads to economic driving by informing the driver of the optimal driving conditions depending on the vehicle's conditions.
(3) It displays that ECO guide and power segment will operate during driving, and also indicates the state of regenerative braking when a
charge zone is instructed while driving.
2. SOC (State Of Charge) guage
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(1) It displays the amount of charge of high-voltage battery.
(2) It displays the charged amount of SOC received from BMS module on the digital gauge in the instrument cluster. (as the below)
Display
Increase (%)
Decrease (%)
Seg0
0
0
Seg1
5
3
Seg2
10
8
Seg3
15
13
Seg4
20
18
Seg5
25
23
Seg6
30
28
Seg7
35
33
Seg8
40
38
Seg9
45
43
Seg10
50
48
Seg11
55
53
Seg12
60
58
Seg13
65
63
Seg14
70
68
Seg15
75
73
Seg16
80
78
Seg17
85
83
Seg18
90
88
3. ECO Level Display
(1) It displays the degree of the driver's economic driving via ECO level.
(2) It displays the ECO level in OLED from Step 1 to 8.
4. Energy Flow
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(1) It displays graphical energy flow of an EV vehicle to inform the driver of the vehicle information.
(2) It leads to economic driving by showing the energy flow diagram by means of intuitive images.
(3) It displays three states of energy flow of the EV vehicle graphically.
(4) VCU module receives operation mode CAN signals to implement any relevant animation.
5. Other indicators and warning lamps
The status between C-CAN transmission modules, operating various indicator and warning lamps on the PS EV cluster, is shown.
Referring to the descriptions below, any checking point or operating point can be identified in the event of a relevant function is
inoperable.
Body Electrical System
Removal
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1. Disconnect the negative (-) battery terminal.
2. Remove the cluster fascia panel.
(Refer to Body - "Cluster Fascia Panel")
3. Remove the cluster (A) after removing screws.
4. Disconnect the cluster connector (A) from the cluster.
Installation
1.
2.
3.
4.
Connect the cluster connector.
Install the cluster assembly.
Install the cluster facia panel.
Connect the negative (-) battery terminal.
- After replacing the cluster with a new one, must be performed the "Variant Coding" procedure.
Inspection
1. Check point (Warning indicator)
NO
1
Ref
Symbol
Color
Name
Signal Input
Green
Turn Left
C-CAN
2
Green
Turn Right
C-CAN
3
Green
Front Fog
C-CAN
Signal Control
(Unit / Sensor)
Check Point
GWAY
1. CAN line failure
GWAY
1. CAN line failure
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4
Blue
High Beam
C-CAN
GWAY
1. CAN line failure
5
Green
Low Beam
C-CAN
GWAY
1. CAN Line failure
6
Green
Tail Lamp
C-CAN
GWAY
1. CAN Line failure
7
Green
Cruise
C-CAN
VCU
1. CAN line failure
8
Green
SET
C-CAN
GWAY
1. CAN line failure
9
Red
Seat Belt
C-CAN
GWAY
1. CAN line failure
10
Red
Air Bag
C-CAN
ACU
1. CAN line failure
11
Yellow
Trunk Open
C-CAN
GWAY
1. CAN line failure
12
Red
Door Open
C-CAN
BGWAY
1. CAN line failure
13
Yellow
Immobilizer
C-CAN
GWAY
1. CAN line failure
2. Wiring failure
14
Yellow
ABS
C-CAN
ESC
1. CAN line failure
15
Yellow
ESC
C-CAN
TCS
1. CAN line failure
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16
Yellow
ESC OFF
C-CAN
TCS
1. CAN line failure
17
Yellow
TPMS
C-CAN
TPMS
1. CAN line failure
18
Red
Parking Brake
C-CAN
GWAY
TCS
AHB
1. CAN line failure
19
Red
Battery Charge
C-CAN
LDC
1. Wiring failure
20
Yellow
Check Engine
C-CAN
EMS
1. CAN line failure
21
Yellow
Low Washer
Hardwire
22
Green
Active ECO
C-CAN
VCU
23
Red
MDPS
C-CAN
MDPS
24
Green
READY
C-CAN
VCU
1. CAN line failure
Green
ＢＭＳ
1. CAN line failure
2. Wiring failure
Red
EMS
1. CAN line failure
Water Level Sensor 1. Wiring failure
1. CAN line failure
2. Wiring failure
1. MDPS unit failure
2. CAN line failure
EV battery charge Hardwire+C-CAN
25
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26
Yellow
EV System
C-CAN
VCU, MCU, BMS,
LDC, FACT, OBC
1. CAN line failure
27
Yellow
Power Down
C-CAN
VCU
1. CAN line failure
28
Yellow
RBS
C-CAN
EBS
29
Yellow
Low Power
C-CAN
VCU
1. CAN line failure
30
Yellow
EPB
C-CAN
EPB
1. CAN line failure
1. CAN line failure
2. Check point (Gauge)
No.
Name
Signal Input
Signal Control
(Unit/Sensor)
Check Point
1
Speedometer
C-CAN
MCU
1. CAN Line failure
2
SOC Gauge
C-CAN
BMS
1. CAN Line failure
3
Power and Charge Gauge
C-CAN
VCU
1. CAN Line failure
3. Check the specified value of cluster connector in specified condition.
No.
Description
Input/Output
Communication
Value (V)
Specified Conditions
1
GND_Signal3
Input
Hardware
Above 5V
IGN switch ON ,
Below 1V
2
ILL(-)_OUT-
Output
Hardware
IGN switch ON, Tail switch ON,
Rheostat Max
9~16V
IGN switch ON, Tail switch ON,
Rheostat Min
3
RheostatSWDown_IN
Input
Hardware
Below 1.5V
Rheostat switch down button push
4
RheostatSWUp_IN
Input
Hardware
Below 1.5V
Rheostat switch up button push
5
Detent_OUT+
Output
Hardware
9~16V
IGN switch ON, Rheostat Max
6
P_OUT+
Output
Hardware
9~16V
IGN On, P position
7
R_OUT+
Output
Hardware
9~16V
IGN On, R position
8
N_OUT+
Output
Hardware
9~16V
IGN On, N position
9
D_OUT+
Output
Hardware
9~16V
IGN On, D position
10
B_OUT+
Output
Hardware
9~16V
IGN On, B position
11
ALTL_OUT
Output
Hardware
12
-
-
-
-
-
13
-
-
-
-
-
14
-
-
-
-
-
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15
AirBag(+)_IN
Output
Hardware
Above 5V
IGN switch ON
16
-
-
-
-
-
17
-
-
-
-
-
SPEED_OUT-
Input
Hardware
9~16V
IGN switch ON/ Vehicel speed
over 1 km/h
19
IGN3
Input
Hardware
Above 9V
Battery charge
20
TailLamp_IN
Input
Hardware
9~16V
Tail switch On
18
21
TripSW(-)_IN
Input
Hardware
Below 1V
Always
22
TripSW1(+)_IN
Output
Hardware
0.56~5V
IGN ON, Push Trip button
23
TripSW2(+)_IN
Output
Hardware
0.56~5V
IGN ON, Push Trip button
24
-
-
-
-
-
25
-
-
-
-
-
9~16V
IGN switch ON
Below 1V
Washer level low
26
LowWasherLevel_IN-
Output
Hardware
27
-
-
-
-
-
9~16V
IGN switch On
Below 1V
Heated wheel switch Push
28
HeatedWheelIND_IN
Output
Hardware
29
MM_CAN_Low
Input
CAN
-
-
30
MM_CAN_High
Input
CAN
-
-
31
-
-
-
-
-
32
C_CAN_High
Input
CAN
-
-
33
C_CAN_Low
Input
CAN
-
-
34
-
-
-
-
-
35
-
-
-
-
-
36
-
-
-
-
-
37
GND_Signal1
Input
Hardware
Below 1V
Always
38
-
-
-
-
-
39
IGN1
Input
Hardware
9~16V
IGN switch ON
40
B+
Input
Hardware
9~16V
Always
Diagnosis with GDS
1. It will be able to diagnose defects of CLU with GDS quickly. GDS can operates actuator forcefully, input/output value monitoring and self
diagnosis.
2. Select model and "BCM".
3. Select the "Cluster Module" to check.
4. Select "Input/output monitoring", if you will check current data of instrument cluster.
5. If you will check each module data operation forcefully, select "Actuation test".
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6. To check the DTC of the each module, select "DIAGNOSTIC TROUBLE CODES".
CLU Variant Coding
After replacing the cluster with a new one, must be performed the “Variant Coding” procedure.
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel, turn the power on GDS.
2. Select model and "BCM".
3. Select Variant coding mode to perform.
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4. If the trouble codes occurred when performing variant coding, try the CLU variant coding again after checking the installation status of
CLU system.
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Body Electrical System
Troubleshooting
Fault item
Symptom
Check point
Related parts
1. Check the connection between connectors
2. Check th Batter (+), Igntion and Ground wiring
3. Check the parts
Connectors, Wiring, Fuse
and Cluster
Display
OLED-LCD NOT displaying
Airbag Warning
indicator
1. Check the Airbag (+) signal (Connector)
Airbag warning indicator NOT
2. Check the C-CAN signal
light
3. Check the connection stuts of FPC
Mode change
Trip mode malfunction
1. Check the switch input terminal (Connector)
2. Chech the signal input (Open or short)
3. Check the mode change of cluster
Switch connector, Wiring
and Cluster
Illumination
Illumination NOT changing
1. Check whehter rheostat input signal input by connector
2. Check Illumination (-) and Detent signal output
3. Check Tail (+) signal input
Switch connector, Wiring
and Cluster
Cluster Warning
sound
Cluster warning sound NOT
sound
1. Check the connector of speaker output terminal
2. Check the intalled speaker on the vehicel
Switch connector, Wiring
and Cluster
Body Electrical System
Specification
Item
Specification
Rating voltage
DC 3V
Operating voltage
DC 2.7V ~ 3.3V
Operating temperature
-20°C ~ +60°C (-4°F ~ +140°F)
RF Modulation
FSK
LF Modulation
ASK
RF frequency
433.92 MHz
Battery
CR2032 (3V / 1EA)
ACU connector, Wiring,
Fuse and Cluster
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Transmissible distance
30m or more
Life of battery
2 years or more (at 20 times per day)
Button number
3
Door lock
Function
Door unlock
Tailgate open
Body Electrical System
Component Location
1. BCM & RF receiver
2. Key warning switch
3. Front door lock actuator & switch
Body Electrical System
4. Rear door lock actuator & switch
5. Tailgate open switch
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Inspection
Front Door Lock Module Inspection
1. Remove the front door trim.
(Refer to Body - "Front Door Trim")
2. Remove the front door module.
(Refer to Body - "Front Door Module")
3. Disconnect the connectors from the actuator.
4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery
voltage only momentarily.
[Central Lock]
5. Check for continuity between the terminals in each switch position according to the table.
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Rear Door Lock Module Inspection
1. Remove the rear door trim.
(Refer to Body - "Rear Door Trim")
2. Remove the rear door module.
(Refer to Body - "Rear Door Module")
3. Disconnect the connectors from the actuator.
4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery
voltage only momentarily.
[Central Lock]
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5. Check for continuity between the terminals in each switch position according to the table.
Tailgate Lock Module Inspection
1. Remove the tailgate trim.
(Refer to Body - "Tailgate Trim")
2. Disconnect the 4P connector from the actuator.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery
voltage only momentarily.
Tailgate Open Switch
1. Remove the tailgate trim.
(Refer to Body - "Tailgate Trim")
2. Disconnect the connector from the actuator.
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3. Check for continuity between the terminals in each switch position according to the table.
Body Electrical System
Specifications
Items
Bulb Wattage (W)
Bulb Type
Head lamp (High)
H7LL
55
Head lamp (Low)
H7LL
55
Turn signal lamp
LED
LED
Position lmap
LED
LED
Fog lamp
55
9006
DRL
LED
LED
W5W
Front
Rear
Side marker
5
Side repeater lamp (O/S mirror)
LED
LED
Tail/Stop lamp
LED
LED
Tail lamp and side marker
LED
LED
Turn signal lamp
27
PY27W
Back up lamp
16
W16W
License plate lamp
5
W5W
High mounted stop lamp
LED
LED
Map lamp
8
FESTOON
FESTOON
Room lamp
8
Vanity lamp
5
FESTOON
Glove box lamp
5
FESTOON
Luggage lamp
8
FESTOON
Body Electrical System
Component Location
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1. Head lamp (Low)
2. Head lamp (High)
3. DRL & Position lamp
4. Turn signal lamp
5. Front fog lamp
6. Turn signal lamp (Outside mirror)
7. Over head console lamp
8. Room lamp
9. Personal lamp
10. Side marker
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1. Tail lamp and side marker
2. Tail / Stop lamp and side marker
3. Turn signal lamp
4. Back up lamp
Body Electrical System
Component
5. High mounting stop lamp
6. License plate lamp
7. Luggage lamp
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1. Head lamp lens & housing assembly
2. Head lamp high beam bulb
3. Head lamp high beam bulb socket
4. Dust cap (High)
5. Head lamp low beam bulb
6. Head lamp low beam bulb socket
7. Dust cap (Low)
8. Side maker
Body Electrical System
Removal
Head lamps become very hot during use; do not touch them or any attaching hardware immediately after they have been turned off.
The headlamp bulb should not be removed from the headlamp assembly until just before a new bulb is installed.
Removing bulb for an extended period of time may affect headlamp bulb performance.
Contaminants may enter the headlamp assembly where they can settle on the lens and reflector.
Never turn on the head lamps with the bulb removed from the headlamp assembly.
1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
3. Loosen the mounting bolts (3EA) of head lamp. Remove the head lamp assembly (B) after disconnecting the lamp connectors (A).
[LH]
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[RH]
Take care that retaining clip (A) is not to be damaged.
Installation
1. Install the head lamp bulbs.
2. Reassemble the head lamp bulb covers.
3. Reassemble the head lamp assembly after connecting the lamp connector.
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Replacement
Head Lamp Low Beam (Bulb)
1. Turn the head lamp switch off.
2. Disconnect the power connector from the lamp.
3. Remove the dust cap (A).
4. Remove the sockect (A) from the head lamp assembly.
5. Remove the bulb (A) from the connector.
6. Installation is the reverse of removal.
Head Lamp High Beam (Bulb)
1. Turn the head lamp switch off.
2. Disconnect the power connector from the lamp.
3. Remove the dust cap (A).
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4. Disconnect the connector (A) from the bulb.
5. Remove the head lamp high beam bulb (A).
6. Installation is the reverse of removal.
Head Lamp Aiming Instructions
The head lamps should be aimed with the proper beam-setting equipment, and in accordance with the equipment manufacturer's
instructions.
If there are any regulations pertinent to the aiming of head lamps in the area where the vehicle is to be used, adjust so as to meet those
requirements.
Alternately turn the adjusting gear to adjust the head lamp aiming. If beam-setting equipment is not available, proceed as follows:
1.
2.
3.
4.
Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and tools.
The vehicle should be placed on a flat floor.
Draw vertical lines (Vertical lines passing through respective head lamp centers) on the screen.
With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on the vertical lines.
A : Low/High beam vertical
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Front Fog Lamp Aiming
The front fog lamps should be aimed as the same manner of the head lamps aiming.
With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting screw hole (A) with a driver.
Head Lamp And Fog Lamp Aiming Point
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General / Euroupe
1. Head Lamp (Low beam)
A. Turn the low beam on without driver aboard.
B. The cut-off line should be projected in the cut-off line shown in the picture.
2. Turn the front fog lamp on without the driver aboard.
The cut-off line should be projected in the allowable range (shaded region)
Body Electrical System
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Removal
Door Mirror Turn Signal Lamp
1. Disconnect the negative (-) battery terminal.
2. Remove the mirror holder (A) from the outside mirror assembly.
3. Remove the door mirror cover (A).
Be careful not to damage the fixing clip
4. Loosen the mirror turn signal lamp mounting screw (A).
5. Remove the door mirror turn signal lamp (B) after disconnecting the connector (A).
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Installation
Door Mirror Turn Signal Lamp
1.
2.
3.
4.
Install the door mirror turn signal lamp.
Install the door mirror cover.
Install the door mirror.
Connect the negative (-) battery terminal.
Body Electrical System
Inspection
1. Check that the switch operates properly after disconnecting the room lamp connector (A).
Room Lamp
Removal
Room Lamp
1. Disconnect the negative (-) battery terminal.
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2. Detach the lamp lens (A) from the room lamp with a flat-tip screwdriver.
3. Separate the room lamp (A) from the roof trim after loosening the screws (2EA).
4. Remove the room lamp (B) after disconnecting the connector (A).
5. If it is necessary to replace the bulb, replace the bulb (A) after detching the lamp lens.
Vanity Lamp
1. Disconnect the negative (-) battery terminal.
2. Remove the vanity lamp assembly (A).
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3. Remove the vanity lamp assembly (B) after disconnecting the connector (A).
4. If it is necessary to replace the bulb, replace the bulb (A).
Installation
Room Lamp
1. Install the room lamp assembly after connecting the lamp connector.
2. Install the lens after assembling the bulb.
Vanity Lamp
1. Install the vanity lamp assembly after connecting the lamp connector.
Body Electrical System
Inspection
1. Remove the overhead console lamp assembly then check for continuity between terminals. If the continuity is not as specified, replace
the map lamp switch.
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No.
Description
1
Ground (-)
2
Door (-)
3
Room/ Door (-)
4
Battery (+)
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the mounting screws (2EA).
And then remove the overhead console (A).
3. Remove the overhead console after disconnect the connectors (A).
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4. If it is necessary to replace the bulb, replace the bulb (in the order as below).
(1) Remove the overhead console lens (A).
(2) Remove the bulb (A).
Installation
1. Install the overhead console lamp after connecting the connector.
2. Install the lens after tightening 2 screws.
Body Electrical System
Inspection
1. The SJB can be diagnosed by using the GDS. The SJB communicates with the GDS which then displays inputs and outputs along with
codes.
It will be able to diagnose defects of hazard lamp switch with GDS quickly. GDS can operates actuator forcefully, input/output value
monitoring and self diagnosis.
2. To diagnose the SJB function, select the vehicle model, BCM and SJB.
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3. To consult the present input/output value of SJB, "Current DATA", provides information of SJB input/output conditions.
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the center airvent assembly (A).
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3. Disconnect the connector (A) from the center airvent assembly.
4. Remove the hazard switch (A) from the center airvent assembly.
Installation
1. Install the hazard switch in the center airvent assembly.
2. Connect the connector and install the center airvent assembly.
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3. Connect the negative (-) battery terminal.
Body Electrical System
Inspection
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the lower crash pad switch assembly (A) by pushing it.
4. Disconnect the connectors (A) from the lower crash pad switch assembly.
5. Remove the rheostat switch (A).
6. Check for intensity of rheostat switch. If the light intensity of the lamps changes smoothly without any flickering when the rheostat is
turned, it can be assumed that the rheostat is normal.
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Body Electrical System
Inspection
Fog Lamp Switch
1. With the fog lamp switch in each position, make sure that continuity exists between the terminals below. If continuity is not as specified,
replace the multifunction switch.
Removal
Front Fog Lamp
1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper.
(Refer to Body - "Front Bumper Cover")
3. Remove the front fog lamp assembly (A) after loosening the mounting screws.
4. Remove the front fog lamp bulb (A) by turning in the counter clock-wise direction.
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Installation
1. Install the front fog lamp bulb.
2. Connect the front fog lamp connector.
3. Install the front bumper cover.
Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the license lamp assembly (A).
3. Replace the bulb (B) after removing the license lamp (A).
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Installation
1. Install the bulb.
2. Install the license lamp assembly.
Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the high mounted stop lamp trim (A).
3. Detach the high mounted stop lamp (A) from the tailgate after loosening the mounting bolts.
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4. Remove the high mounted stop lamp (C) after disconnecting the connector (B) and hose (A).
Installation
1. Install the high mounted stop lamp.
2. Install the high mounted stop lamp trim.
3. Connect the negative (-) battery terminal.
Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Using a screwdriver or remover, remove the luggage lamp (A).
3. Remove the luggage lamp (A) after disconnecting the connector (B).
Installation
1. Install the luggage lamp assembly after connecting the lamp connector.
Body Electrical System
Removal
Rear Combination Lamp
1. Disconnect the negative (-) battery terminal.
2. Remove the rear combination lamp (A) after loosening the mounting screws.
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3. Disconnect the rear combination lamp connector (A).
Turn Signal Lamp Bulb
1. Disconnect the negative (-) battery terminal.
2. Remove the rear combination lamp assembly.
3. Remove the turn signal lamp socket (A) by turning the socket counterclockwise.
4. Remove the turn signal lamp bulb (A).
Back Up Lamp Bulb
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1. Disconnect the negative (-) battery terminal.
2. Remove the rear combination lamp assembly.
3. Remove the back up lamp socket (A) by turning the socket counterclockwise.
4. Remove the back up lamp bulb (A).
Installation
1. Install the rear combination lamp assembly.
2. Connect the negative (-) battery terminal.
Body Electrical System
Components
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Body Electrical System
Circuit Diagram
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Body Electrical System
Removal
[Sound Mood Lamp Unit]
1. Disconnect the negative (-) battery terminal.
2. Remove the audio head unit.
(Refer to Body Electrical - "Audio unit")
3. Disconnect the connector (A) from the mood lamp unit.
4. Remove the sound mood lamp unit (A) after loosening the mounting nut.
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[Sound Mood Lamp Switch]
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the lower crash pad switch assembly (A) by pushing it.
4. Disconnect the connectors (A) from the lower crash pad switch assembly.
5. Remove the rheostat switch (A).
Installation
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[Sound Mood Lamp Unit]
1. Install the mood lamp unit.
2. Install the audio head unit.
3. Connect the negative (-) battery terminal.
[Sound Mood Lamp Switch]
1. Connect the connectors and install the mood lamp switch.
2. Install the crash pad lower panel.
3. Connect the negative (-) battery terminal.
Body Electrical System
Components
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Using the flat screw driver or remover, remove the crash pad center air vent panel (A).
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3. Disconnect the hazard switch connector (A).
4. Remove center fascia upper panel (A) after loosening the mounting screws.
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5. Disconnect the charge information lamp connector (A).
6. Remove the charge information lamp assembly (A) after loosening the mounting screws.
Installation
1. Install the charge information lamp assembly, center fascia upper panel and crash pad center air vent panel.
2. Connect the negative (-) battery terminal.
Body Electrical System
Troubleshooting
Symptom
Possible cause
Remedy
One lamp does not light
(all exterior)
Bulb burned out
Replace bulb
Socket, wiring or ground faulty
Repair if necessary
Head lamps do not light
Bulb burned out
Replace bulb
Ignition fuse (LOW:10A, HIGH:20A) blown
Check for short and replace fuse
Head lamp fuse (15A) blown
Check for short and replace fuse
Head lamp relay faulty
Check relay
Lighting switch faulty
Check switch
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Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Tail lamp fuse (10A) blown
Check for short and replace fuse
Tail lamps and license plate lamps do not light Tail lamp relay faulty
Lighting switch faulty
Stop lamps do not light
Check relay
Check switch
Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Stop lamp fuse (15A) blown
Check for short and replace fuse
Stop lamp switch faulty
Adjust or replace switch
Wiring or ground faulty
Repair if necessary
Stop lamps do not turn off
Stop lamp switch faulty
Repair or replace switch
Instrument lamps do not light
(Tail lamps light)
Rheostat faulty
Check rheostat
Turn signal lamp does not flash on one side
Turn signal lamps do not light
Hazard warning lamps do not light
Flasher rate too slow or too fast
Back up lamps do not light
Room lamp does not light
Front fog lamps do not light
Wiring or ground faulty
Map lamp does not light
Trunk room lamp does not light
Body Electrical System
Specifications
Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Turn signal switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Turn signal lamp fuse (10A) blown
Check for short and replace fuse
Flasher unit faulty
Check flasher unit
Turn signal switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Hazard warning lamp fuse (15A) blown
Check for short and replace fuse
Flasher unit faulty
Check flasher unit
Hazard switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Lamps' wattages are smaller or larger than
specified
Replace lamps
Flasher unit faulty
Check flasher unit
Bulb burned out
Replace bulb
Back up lamp fuse (10A) blown
Check for short and replace fuse
Back up lamp switch (M/T) faulty
Check switch
Transaxle range switch (A/T) faulty
Check switch
Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Room lamp fuse (10A) blown
Check for short and replace fuse
Room lamp switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Front fog lamp fuse (15A) blown
Check for short and replace fuse
Front fog lamp relay faulty
Check relay
Front fog lamp switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Repair if necessary
Bulb burned out
Replace bulb
Room lamp fuse (10A) blown
Check for short and replace fuse
Map lamp switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
Bulb burned out
Replace bulb
Room lamp fuse (10A) blown
Check for short and replace fuse
Trunk room lamp switch faulty
Check switch
Wiring or ground faulty
Repair if necessary
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Items
Specifications
Rated voltage
DC 12V
Operating temperature range
-30°C ~ +80°C (-22 ~ +176°F)
High : 1A (Relay load)
Dimmer & passing switch
Low : 1A (Relay load)
Passing : 1A (Relay load)
Lighting switch/ Auto lighting switch
Turn signal & lane change switch
Rated load
Front / Rear fog lamp switch
1A (Relay load)
6.6 ± 0.5A (Lamp load)
1A (Relay load)
Low, High : 4.0A (Motor load)
Wiper switch
Intermittent : 0.22 ± 0.05A (Relay load)
Lock : Max. 28A (Motor load)
Mist switch
Front/Rear washer switch
Rear wiper
Body Electrical System
Component
Mist : 4A (Motor load)
4A (Motor load)
0.2A (Relay load)
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the steering wheel.
(Refer to Steering System - "Steering Wheel")
3. Remove the steering column upper and lower shrouds.
(Refer to Body - "Steering Column Shroud Panel")
4. Remove the clock spring.
(Refer to Restraint - "Driver Airbag (DAB) Module and Clock Spring")
5. Disconnect the light switch connector (A) and the wiper switch connector (B).
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6. Remove the wiper switch (A) by pushing the lock pin (B).
When removing the wiper & washer switch only, release the lock of wiper switch without removing the steering wheel.
7. Loosen the screws from the multifunction switch assembly (A).
Installation
1.
2.
3.
4.
Install the multifunction switch.
Install the clock spring.
Install the steering column upper and lower shrouds.
Install the steering wheel.
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5. Connect the negative (-) battery terminal.
Make sure the multifunction switch connectors are plugged in properly.
Inspection
Lighting Switch Inspection
1. With the multi function switch in each position, make sure that continuity exists between the terminals below.
If continuity is not as specified, replace the multi-function switch
Lighting switch (Auto light)
Lighting Switch
Dimmer And Passing Switch
Turn Signal Switch
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Front Fog Lamp
Wiper And Washer Switch Inspection
1. With the multi function switch in each position, make sure that continuity exists between the terminals below.
If continuity is not as specified, replace the multi-function switch.
Wiper Switch
Washer Switch
Rear Wiper Switch
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Rear Washer Switch
Inspection (With GDS)
1. Check IPM input/output specification of multifunction switch using the GDS. If the specification is abnormal, replace the lamp or wiper
switch.
2. If diagnosis is required on the multifunction switch, select model and "IPM".
3. Select "Current data" and check the input/output condition of "Multifunction switch".
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4. To perform test on "Multifunction switch" outputs, select "Actuation test".
Body Electrical System
Specifications
Item
Specification
Rated voltage
Operation range
Operation voltage
Front/Rear parking assist system control Operation current
unit
Operation temperature
Operation frequency
Number of sensors
DC 12V
30~120 cm(11.8~47.2 in)
DC 9V~16V
Max. 300 mA
-30~+80 °C
48 ± 5 KHz
Front : 4EA(Left, Right, Center left, Center right)
Rear : 4EA(Left, Right, Center left, Center right)
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Body Electrical System
Component Location
1. BCM
2. Ultrasonic sensor
※ Parking assist control unit function and buzzer are built in BCM (body control unit).
Body Electrical System
System Configuration
PAS consists of 8 sensors(Front 4 EA, Rear 4EA) which are detecting the obstacles and transmit the result separated into three warning
levels, the first, second and third to IPM(BCM) by Lin communication. IPM(BCM) decides the alarm level by the transmitted communication
message from the slave sensors, then operate the buzzer or transmits the data for display.
Block Diagram
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System Operation Specification
1. Initial mode - Front sensor
(1) System initializing time is 500ms after IGN1+ initial D Gear + below 10 Km/h .
(2) PAS recognizes LID and sets the sensor ID up during initialization.
(3) PAS activates each sensor and then executes the diagnosis after finishing initialization of IPM(BCM).
(4) PAS Starting buzzer” is normally worked, when sensor does not send an error message and after finishing error diagnosis.
(5) If any failure is received from the any sensors, PAS Starting Buzzer” does not work but the failure alarm is operated for a moment.
If you have display option, warning sign is also shown on it.
(6) Buzzer for sensor failure is operated once, but display is shown continuously until it is repaired completely.
(7) IPM(BCM) memorizes the completed initializing status of front sensor until IGN 1 is OFF. It doesn't activate initializing when next D
gear input.
(8) In case of PAS SW OFF, system initializing does not be activated.
(9) If PAS switch is ON like as below status, it activates initializing.
A. PAS switch OFF when IGN1 is On.
B. PAS switch ON when vehicle speed is below 10 km/h
(10) Initializing has nothing to do with parking brake operation.
2. Initial mode - Rear sensor
(1) System initializing time is 500ms after IGN1+ initial R Gear.
(2) PAS recognizes LID and sets the sensor ID up during initialization.
(3) PAS activates each sensor and then executes the diagnosis after finishing initialization of IPM(BCM).
(4) PAS Starting buzzer” is normally worked, when sensor does not send an error message and after finishing error diagnosis.
(5) If any failure is received from the any sensors, PAS Starting Buzzer” does not work but the failure alarm is operated for a moment.
If you have display option, warning sign is also shown on it.
(6) Buzzer for sensor failure is operated once, but display is shown continuously until it is repaired completely.
(7) IPM(BCM) memorizes the completed initializing status of rear sensor until IGN 1 is OFF. It doesn't activate initializing when next R
gear input.
(8) Initializing has nothing to do with parking brake operation.
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3. Normal mode - Front sensor
(1) Lin communication starts and keeps the routine after IGN1 ON+D gear + below 10 km/h.
(2) After initializing, the routine starts at once without PAS starting warning sound.
(3) Alarms of obstacle consists of 3 level 1,2,3 step and 1,2 alarm sounds intermittently and 3 alarm sounds continuously. 1 level alarm
doesn't exist in the front ultrasonic sensor.
A. Type with display
• 2 level alarm : Display is only operated without alarm.
• 3 level alarm : Alarm + Display
B. Type without display : Alarm only
(4) In display, the data of each sensor is sent from IPM(BCM) to display, for example cluster. CAN communication is used for
transmission and maximum gateway time is 50ms.
(5) The efficient vehicle speed of RPAS operation is under 10Km/h.
(6) It doesn't work at PAS SW OFF.
(7) It has nothing to do with parking brake operation.
(8) Operation doesn't start or stops at gear N, P.
4. Normal mode - Rear sensor
(1) Lin communication starts and keeps the routine after IGN1 ON+R gear
(2) BCM send a message once to each sensor for operating request to check the initial status of the system and four sensors response
at a time. At this time, if there is no problem, the alarm starts after 500ms of R gear shifting at 300ms intervals.
(3) After initialization, normal mode starts 100ms later after finishing alarm output.
(4) Alarm for obstacles is divided into 3 levels.
The first and second are intermittent sound, and the third alarms continuously
(5) In display, the data of each sensor is sent from BCM to display, for example Cluster.
CAN communication is used for transmission and maximum gateway time is 50ms.
(6) It has nothing to do with vehicle speed.
(7) When PAS SW is OFF, if gear R signal is inputted, PAS SW is changed to ON.
(8) It has nothing to do with parking brake operation.
(9) Operation doesn't start or stops at gear N, P.
Sensing Area
1. Measurement condition – PVC pole (diameter 75mm, length 3m), normal temperature
2. Distance range detected objects (Measured directly in front of sensor)
Position
Level
1st
Front
Rear
Distance range
cm
inch
61 ~100 (±15)
24.0 ~ 39.4 (±5.9)
2nd
31 ~ 60 (±15)
12.2 ~ 23.6 (±5.9)
3rd
Less than 30 (±10)
Less than 11.8 (±3.9)
24.0 ~ 47.2 (±5.9)
1st
61 ~120 (±15)
2nd
31 ~ 60 (±15)
12.2 ~ 23.6 (±5.9)
3rd
Less than 30 (±10)
Less than 11.8 (±3.9)
Horizontal Sensing Area
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Vertical Sensing Area
Distance Measurement
Direct Measurement
Transmission and Reception are executed with one sensor
(FL, FCL, FCR, FR, RL, RCL, RCR, RR each sensor execution)
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Indirect Measurement
(FCL → FL, FCL → FCR, FCR → FCL, FCR → FR, RCL → RL, RCL → RCR, RCR → RCL, RCR → RR Execution in order)
With two or three sensors, one of them sends the transmission and the others get the reception.
Direct and Indirect Measurement at once
With two or three sensors, the one sensor performs both transmission and reception, and the others perform only reception.
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RPAS alarm system
When the RPAS sensor detects the object, warning is operated by audible alarm device as like buzzer. RPAS sensor sends data to BCM
with LIN communication and BCM implements audible warning for each RPAS SENSOR by priority. And it performs a role of gateway only
when it sends visible alarm device such as Cluster.
- Sensor buzzer/display information processing method of BCM In case of RL/RR sensor information, the BCM handles each sensor
information directly about Display and buzzer output function. Buzzer output of CL/CR sensor, BCM handles center combination
information by priority both sensor, Otherwise, about fail display information,BCM send that to cluster each sensor information.
System operation Spec - Front sensor
When the system has the power (after IGN ON and D gear), MICOM checks every sensor channel. In case it is not find any error, it sounds
500ms afterward. But it finds any error even a sensor, it sounds buzzer corresponding fault sensor instead of initial starting alarm. If PAS ON
switch in OFF, system doesn't work. Function for normal mode entrance is as below.
* In the initial mode, IPM(BCM) judges only sensor fail.
With D gear, system function is as below.
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With D gear releasing, system function is as below
System Operation Spec - Rear sensor
When the system has the power (after IGN ON and R gear), MICOM checks every sensor channel.In case it is not find any error, it sounds
300ms buzzer 500ms afterward.But it finds any error even a sensor, it sounds buzzer corresponding fault sensor instead of initial starting
alarm. Function for normal mode entrance is as below
With R Gear, system function is as below
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With R gear releasing, system function is as below
※acceptable error range on waveform ±10%
Alarm Output Specification classified by distance between sensors
Condition logic according to priority of alarm level is as below. (the identical sensor)
*α value definition
1. low priority sensor off : α = 0ms
2. low priority sensor is 1st warning level : α < 340ms
3. low priority sensor is 2nd warning level : α < 170ms
*β value definition
1. low priority sensor is 1st warning level : β = 1700ms
2. low priority sensor is 2nd warning level : β = 1700ms
3. low priority sensor is 3rd warning level : β = 700ms
Alarm control by sensing distance is as below
1. First warning area (Front: 61cm(24in) ~ 100cm(39.4in), Rear: 81cm(31.9in) ~ 120cm(47.2in) )
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2. Second warning area (Front: 31cm(12.2in) ~ 60cm(23.6in), Rear: 41cm(16.1in) ~ 80cm(31.5in) )
3. Third warning area (Front: less than 20cm(7.9in). Rear: less than 40cm(15.7in))
4. Period of fault alarm
(1) With visible display
Visible Alarm Indicator Specification.
Front alarm display
When the system operates, cluster lights the indicator as below figure.
When the system finds an object, it lights indicator immediately.
1. Alarm level per distance - Front sensor
A. First step alarm : 61~100 cm(24~39.4 in)
B. Second step alarm : 31~60 cm(12.2~23.6 in)
C. Third step alarm : Less than 30 cm(11.8 in)
* It only displays the position of detected obstacle.
* Indicator blinks every 1 second at third step alarm.
Rear alarm display
1. Alarm level per distance - Rear sensor
When the gear is applied to R, cluster lights the indicator as below figure.When the system finds an object, it lights indicator immediately.
During sensing an object, if there is no object, it lights indicator that is no alarm status for two seconds and then turns out afterward
detecting an object.(But when it turns third step alarm to No alarm status, it lights third step alarm for two second and turns out.)
A. First step alarm : 61~120 cm(24~39.4 in)
B. Second step alarm : 31~60 cm(12.2~23.6 in)
C. Third step alarm : Less than 30 cm(11.8 in)
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* It only displays the position of detected obstacle.
* Indicator blinks every 1 second at third step alarm.
* Integrated display(FCL/FCR, RCL/RCR)
Error Handling
LIN BUS Off error case
Section
Initial Routine
Normal Routine
Error recognition condition
Error releasing condition
LIN BUS OFF sensing once
Error is not released in initial mode.
LIN BUS OFF is sensed times in a row
The fault is released when BCM or LIN Master senses
LIN BUS ON four times in a row in normal mode
※ Remark :
1. In fault counting, output message or signal should be transmitted as a Last Valid value.
2. Error in initial mode, fault buzzer (BCM) is operated with fault display(Cluster)
3. Error in normal mode, fault is only displayed on Cluster without buzzer.
Sensor fault (LIN Msg : 0x08)
Section
Initial Routine
Normal Routine
Error recognition condition
Error releasing condition
Sensor fault Message sensing once
Error is not released in initial mode.
Sensor fault Message sensing four times in a row
The fault is released when BCM or LIN Master senses
LIN BUS ON four times in a row in normal mode
※ In fault display, RCR/RCL indicator is displayed individually
※ Remark :
1. In fault counting, output message or signal should be transmitted as a Last Valid value.
2. Error in initial mode, fault buzzer (BCM) is operated with fault display (Cluster)
3. Error in normal mode, fault is only displayed on Cluster without buzzer
4. When the error occurs in direct condition, the sensors sent the same status of error for indirect condition
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Body Electrical System
Circuit Diagram
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the front/rear bumper cover.
(Refer to Body - "Front Bumper Cover")
(Refer to Body - "Rear Bumper Cover")
3. Disconnect the connector (A) from the ultrasonic sensor.
[Front sensor, Rear center sensor]
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[Rear side sensor]
4. Pull out ths ultrasonic sensor (A) by opening the sensor holder out.
[Front sensor, Rear center sensor]
[Rear side sensor]
Installation
1. Install the PAS sensor and connector.
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2. Install the front/rear bumper cover.
Body Electrical System
Component Location
1. Driver power window main switch
2. BCM (Body Control Module)
3. Door lock switch
Body Electrical System
Inspection
Front Door Lock Module Inspection
1. Remove the front door trim.
4. Front door lock actuator & switch
5. Rear door lock actuator & switch
6. Tailgate lock actuator & switch
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(Refer to Body - "Front Door Trim")
2. Remove the front door module.
(Refer to Body - "Front Door Module")
3. Disconnect the connectors from the actuator.
4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery
voltage only momentarily.
[Central Lock]
5. Check for continuity between the terminals in each switch position according to the table.
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Rear Door Lock Module Inspection
1. Remove the rear door trim.
(Refer to Body - "Rear Door Trim")
2. Remove the rear door module.
(Refer to Body - "Rear Door Module")
3. Disconnect the connectors from the actuator.
4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery
voltage only momentarily.
[Central Lock]
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5. Check for continuity between the terminals in each switch position according to the table.
Tailgate Lock Module Inspection
1. Remove the tailgate trim.
(Refer to Body - "Tailgate Trim")
2. Disconnect the 4P connector from the actuator.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery
voltage only momentarily.
Tailgate Open Switch
1. Remove the tailgate trim.
(Refer to Body - "Tailgate Trim")
2. Disconnect the connector from the actuator.
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3. Check for continuity between the terminals in each switch position according to the table.
Hood Switch
1. Disconnect the connector (A) and bolts from the hood switch.
2. Check for continuity between the terminals and ground according to the table.
Body Electrical System
Diagnosis With GDS
1. The BCM can be diagnosed by using the GDS. The BCM communicates with the GDS which then displays inputs and outputs along with
codes.
It will be able to diagnose power door lock/unlock defects with GDS quickly. GDS can operates the actuator forcefully,monitor
input/output values and self diagnosis.
2. To diagnose the SJB function, select the vehicle model, BCM and DDM.
3. Select "Input/output monitoring", if you will check current data of power door lock system. It provides input/output status of DDM.
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4. To perform functional test on SJB outputs, select "Actuation Test".
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Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim.
(Refer to Body - "Front Door Trim")
3. Remove the power window switch assembly (A) loosening the mounting screws (8EA).
4. Remove the power window switch (A) after loosening the mounting screws (4EA).
Installation
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1. Install the power window switch assembly.
2. Install the front door trim after connect the connector.
Body Electrical System
Component Location
1. Power door mirror
2. Power door mirror switch
Body Electrical System
Components
3. Power folding mirror switch
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Body Electrical System
Circuit Diagram
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Body Electrical System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the front left door trim.
(Refer to Body - "Front Door Trim")
3. Remove the power window switch assembly (A) loosening the mounting screws (8EA).
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4. Remove the power window switch (A) after loosening the mounting screws (4EA).
5. Remove the power mirror switch (A) after loosening the mounting screw (1EA).
Installation
1. Install the power mirror switch.
2. Install the front door trim after connecting the connector.
3. Connect the negative (-) battery terminal.
Inspection
1. Remove the front left door trim.
(Refer to Body - "Front Door Trim")
2. Remove the power mirror switch connector (A) from the door trim.
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3. Check for continuity between the terminals in each switch position according to the table.
[Power Mirror Switch]
[Power Folding Mirror Switch]
Body Electrical System
Inspection
1. Disconnect the negative (-) battery terminal.
2. Remove the front door quadrant cover (A).
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3. Disconnect the power door mirror connector (A) from the harness.
4. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
[Actuator]
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Mirror Heater
Turn Signal Lamp
Folding Mirror
Body Electrical System
Component Location
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1. Drive power window switch
2. Passenge power window switch
3. Front window motor
4. Rear window motor
5. Rear window switch
Body Electrical System
Function Of Safety Power Window
When driver door power window auto-up switch is operated, safety function is activated.
1. Safety function condition
When detect the force of 100N (using the 10N/mm spring) during the window rising, window is reversed.
2. Length of window reversing (except holding the auto-up switch)
A. When detect the jamming during the 4mm ~ 250mm from top of the door.
→ Window is reversed until 300mm from top of the door.
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B. When detect the jamming over the 250mm from top of the door.
→ Window is reversed until 20mm from jamming position.
3. Length of window reversing (holding the auto-up switch)
A. When detect the jamming during holding the auto-up switch.
→ Window is reverse until 25mm from jamming position.
B. Auto-up function is not available during the 5 seconds from above condition.
→ When holding the auto-up switch, window is operated as a manual-up function. (Safety function is not activated.)
C. When holding the auto-up switch after 5 seconds from above condition.
→ Window is reverse until 25mm from jamming position.
4. Safety function is not available area
Safety function is not available during the 4mm from top of the door.
Initializing Method Of The Safety Power Window
1. Initializing of Battery Connection
When the battery power is removed for over 5 minutes, safety power window switch need the initializing.
(1) Power window operation before initializing
A. Manual-Up/Down function is available
B. Auto-Up function is not available
(When holding the auto-up/down switch, window is operated as a manual-up/down.)
(2) Initializing method
Close the window in window open position, and holding the switch in window full close position over the 0.2 second.
(If start the closing the window in window full close position, initializing could be failed.)
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(3) If the initialize state of the safety power window is in jamming status, the condition below can occur.
A. Safety function is not available
2. Initializing of fail safe mode
(1) If the window moved by compulsion and motor have a problem, power window switch could be entering the fail safe mode for user’s
safety.
(2) Power window operation in fail mode
A. Auto/Manual-Down function is available
B. Auto/Manual-Up function is not available
(When auto/manual-up is operated, window is rising 20mm and is stopped the moving.)
Body Electrical System
Components
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Body Electrical System
Inspection
Front Power Window Motor
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim.
(Refer to Body - "Front Door Trim")
3. Disconnect the connector (A) from the motor.
(A : Safety, B : Standard)
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4. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next, reverse the polarity and
check that the motor operates smoothly in the reverse direction. If the operation is abnormal, replace the motor.
[General Window Motor]
5. Connect the terminal No. 2 and No. 3 to battery voltage (12V) and check that the motor operates smoothly when connecting the terminals
below.
[Safety Window Motor]
Rear Power Window Motor
1. Disconnect the negative (-) battery terminal.
2. Remove the rear door trim.
(Refer to Body - "Rear Door Trim")
3. Disconnect the connector (A) from the motor.
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4. Connect the motor terminals directly to battery voltage (12V) and check that the motor operates smoothly. Next, reverse the polarity and
check that the motor operates smoothly in the reverse direction. If the operation is abnormal, replace the motor.
Body Electrical System
Components
Driver Power Window Switch
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Assist Power Window Switch
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Rear Power Window Switch
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Body Electrical System
Circuit Diagram
Driver Power Window Switch
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Assist Power Window Switch
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Rear Power Window Switch
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Body Electrical System
Inspection
Power Window Main Switch Inspection
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim.
(Refer to Body - "Front Door Trim")
3. Disconnect the connector (A) from the power window switch module.
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4. Check for continuity between the terminals in each switch position according to the table.
[Driver/Assist Safety]
[Driver Auto Down]
Assist Power Window Switch Inspection
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim panel.
(Refer to Body - "Front Door Trim")
3. Disconnect the connector (A) from the switch.
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4. Check for continuity between the terminals in each switch position according to the table. If the continuity condition is not normal, replace
the switch.
[Safety]
[Manual]
Rear Power Window Switch Inspection
1. Disconnect the negative (-) battery terminal.
2. Remove the rear door trim panel.
(Refer to Body - "Rear Door Trim")
3. Disconnect the connector (A) from the switch.
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4. Check for continuity between the terminals in each switch position according to the table. If the continuity condition is not normal, replace
the switch.
[With Seat Heater]
[Without Seat Heater]
Removal
Driver Power Window Switch
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim.
(Refer to Body - "Front Door Trim")
3. Remove the power window switch assembly (A) loosening the mounting screws (8EA).
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4. Remove the power window switch assembly (A) after loosening the mounting screws.
Assist Power Window Switch
1. Disconnect the negative (-) battery terminal.
2. Remove the front door trim.
(Refer to Body - "Front Door Trim")
3. Remove the power window switch assembly (A) loosening the mounting screws (7EA).
4. Remove the power window switch assembly (A) after loosening the mounting screws.
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Rear Power Window Swtich
1. Disconnect the negative (-) battery terminal.
2. Remove the rear door trim.
(Refer to Body - "Rear Door Trim")
3. Remove the power window switch assembly (A) loosening the mounting screws (7EA).
4. Remove the power window switch assembly (A) after loosening the mounting screws.
Installation
Driver Power Window Switch
1. Install the power window switch assembly.
2. Install the front door trim after connect the connector.
Assist Power Window Switch
1. Install the power window switch assembly.
2. Install the front door trim after connect the connector.
Rear Power Window Swtich
1. Install the power window switch assembly.
2. Install the rear door trim after connect the connector.
Body Electrical System
Inspection
Diagnosis With GDS
1. It will be able to diagnose defects of power window with GDS quickly. GDS can operates actuator forcefully, input/output value monitoring
and self diagnosis.
2. Select model and "BCM".
3. Select the "SJB" to check.
4. Select "Current data", if you will check current data of power window system. It provides input/output status of SJB.
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5. If you will check the power door lock operation forcefully, select "Actuation test".
Body Electrical System
Component Location
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1. Rear glass defogger relay (Buil-in smart junction box)
2. Rear glass defogger switch (FATC type)
3. Rear glass defogger
Body Electrical System
Inspection
Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure on the tin foil, moving
the tin foil along the grid line to check for open circuits.
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1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center point. If a voltage of
approximately 6V is indicated by the voltmeter, the heater line of the rear window is considered satisfactory.
2. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
3. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V.
4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to find a point where a
voltage is generated or changes to 0V. The point where the voltage has changed is the open-circuit point.
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5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line, and between the same
terminal and the center of one adjacent heater line. The section with a broken heater line will have a resistance twice that in other
sections. In the affected section, move the test lead to a position where the resistance sharply changes.
Repair Of Broken Heater Line
Prepare the following items :
1. Conductive paint.
2. Paint thinner.
3. Masking tape.
4. Silicone remover.
5. Using a thin brush :
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as shown. Shake the
conductive paint container well, and apply three coats with a brush at intervals of about 15 minutes apart. Remove the tape and allow
sufficient time for drying before applying power. For a better finish, scrape away excess deposits with a knife after the paint has
completely dried. (Allow 24 hours).
Body Electrical System
Inspection
1. The windshield deicer switch inputs can be checked using the GDS.
2. To check the input value of windshield deicer switch, select option "Body Control Module".
3. Select option "Current Data".
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4. To perform functional test on SJB outputs, select "Actuation Test".
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the heater and A/C control unit.
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(Refer to Heating, Ventilation, Air Condition - "Heater & A/C Control Untit (FATC))
Installation
1. Install the heater and A/C control unit.
2. Connect the negative (-) battery terminal.
Body Electrical System
Component Location
1. Head cap
2. Rear wiper arm nut
3. Rear wiper arm & blade
Body Electrical System
Inspection
Rear Wiper Motor
1. Remove the connector from the rear wiper motor.
4. Grommet
5. Rear wiper motor assembly
6. Rear wiper motor bolt
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2. Connect battery positive (+) and negative (-) cables to terminals 2 and 1 respectively.
3. Check that the motor operates normally. Replace the motor if it operates abnormally.
No.
Description
1
Battery (+)
2
Parking
3
Ground
4
Signal
Automatic Stop Operation Check
1.
2.
3.
4.
Operate the motor at low speed using the stalk control.
Stop the motor operation anywhere except at the off position by disconnecting terminal 2.
Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1.
Check that the motor stops running at the off position.
Removal
1. Detach the rear wiper cap (A).
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2. Remove the rear wiper arm & blade (B) after removing rear wiper HEX nut (A).
3. Remove the rear wiper grommet (A).
4. Remove the tailgate trim after opening the tailgate.
(Refer to Body - "Tailgate Trim")
5. Disconnect the rear wiper motor connector (A) then remove the rear wiper motor (B) after loosening bolts.
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Installation
1. Install the rear wiper motor assembly.
Tightening torque Bolt :
6.9~10.8 Nm (0.7~1.1 kgf.m, 5.1~8.0 lbf.ft)
2. Install the tailgate trim.
3. Install the rear wiper arm cap after tighting the nut.
Tightening torque Nut :
3.9~6.9 N.m (0.4~0.7 kgf.m, 2.9~5.1 lbf.ft)
4. Set the rear wiper blade and to the lowest defogger heat line and tailgate glass.
A : Auto stop position
Body Electrical System
Inspection
1. Check for continuity between the terminals while operating the wiper and washer switch. If it is not normal condition, replace wiper and
wiper switch.
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Rear Wiper Switch
Rear Washer Switch
Body Electrical System
Inspection
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
Before filling the reservoir tank with water, check the filter for foreign material or contamination. if necessary, clean the filter.
2. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
3. Connect positive (+) and negative (-) battery cables to terminals 1 and 2 respectively to see that the washer motor runs and water is
pumped.
4. Check that the motor operates normally.
Replace the motor if it operates abnormally.
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Body Electrical System
Components
[First Row Seat]
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Connector Pin Information
Pin No.
Connector A
Connector B
Connector C
1
Illumination (+)
Ground
Electric compressor - interlock (+)
2
Sensor REF (+5V)
Sensor ground
Electric compressor - interlock (-)
3
C_CAN High
PWM blower IN
High voltage PTC heater - interlock (+)
4
C_CAN LOW
Cluster ionizer diagnosis
High voltage PTC heater - interlcok (-)
5
Driver mode actuator (VENT)
-
PAB IGN3
6
Driver mode actuator (DEF)
CLEAN signal
PAB ON signal
PAB OFF signal
7
Driver mode actuator F/B
Assist mode actuator (VENT)
8
Intake actuator (FRE)
Assist mode actuator (DEF)
SBR
9
Intake actuator (REC)
Assist mode actuator F/B
Rr LEFT SBR
10
Extake actuator F/B
DEF actuator (OPEN)
Rr CENTER SBR
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11
K-LINE
DEF actuator (CLOSE)
12
HTD
DEF actuator F/B
-
13
Rear defog switch
Vent left duct sensor (+)
-
14
Temperature control actuator (COOL)
Floor left duct sensor (+)
-
15
Temperature control actuator (WARM)
IGN3
-
16
Temperature control actuator F/B
IGN2
-
17
Driver seat heater indicator - LOW
-
18
Driver seat heater indicator - MID
2 WAY valve #1 (+)
19
Driver seat heater indicator - HIGH
3 WAY valve #1 (+)
20
Illumination (RHEO)
3 WAY valve #2 (+)
21
DETENT OUT (+)
2 WAY valve #2 (+)
22
Driver seat heater switch
CLIMATE_CAN HIGH
23
Driver cooler seat indicator - LOW
CLIMATE_CAN LOW
24
Driver cooler seat indicator - MID
HUMIDITY (PWM)
25
Driver cooler seat indicator - HIGH
Air pressor tranduser signal
26
Assist seat heater switch
Refrigerant temperature sensor signal
#1
27
Ambient sensor (+)
Refrigerant temperature sensor signal
#2
28
EVAP sensor (+)
Coolant 3way valve output
29
Assist cooler seat indicator - LOW
IGN3
30
Assist cooler seat indicator - MID
Blower IS
31
Assist cooler seat indicator - HIGH
Battery
32
Photo sensor (-)
Battery
33
Assist cooler switch
34
Driver cooler switch
35
Blower INH
36
MM_CAN HIGH
37
MM_CAN LOW
38
Assist seat heater indicator - LOW
39
Assist seat heater indicator - MID
40
Assist seat heater indicator - HIGH
Second Row Seat
Rr RIGHT SBR
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Body Electrical System
Circuit Diagram
[First Row Seat]
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Second Row Seat
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Body Electrical System
Removal
First Row Seat
1. Remove the heater & A/C control unit.
(Refer to Heating, Ventilation And Air Conditioning - "Heater & A/C Control Unit (FATC)")
Second Row Seat
1. Disconnect the negative (-) battery terminal.
2. Remove the rear door trim.
(Refer to Body - "Rear Door Trim")
3. Remove the power window switch assembly (A) loosening the mounting screws (7EA).
Installation
First Row Seat
1. Install the heater & A/C control unit.
(Refer to Heating, Ventilation And Air Conditioning - "Heater & A/C Control Unit (FATC)")
Second Row Seat
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1. Install the power window switch.
2. Install the rear door trim.
3. Connect the negative (-) battery terminal.
Inspection
First Row Seat
1. Disconnect the negative (-) batttery terminal.
2. Disconnect the A/C & heater controller connectors (A).
(Refer to Heating, Ventilation And Air Conditioning - "Heater & A/C Control Unit (FATC)")
3. Operate switch and check that continuity exists between the terminals.
If there is no continuity, replace the seat heater switch.
Second Row Seat
1. Disconnect the negative (-) batttery terminal.
2. Remove the rear door trim.
(Refer to Body - "Rear Door Trim")
3. Operate driver seat heater switch and check that continuity exists between the terminals.
If there is no continuity, replace the seat heater switch.
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Body Electrical System
Components
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Body Electrical System
Circuit Diagram
[First Row Seat]
[Second Row Seat]
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Body Electrical System
Inspection
First Row Seat
1. Check for continuity and measure the resistance between terminals.
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Resistanc
(± 10%)
Connector
Cushion (C)
1-2
4.54 Ω
Back (B)
1-2
5.16 Ω
Set (A)
1-4
9.70 Ω
Second Row Seat
1. Check for continuity and measure the resistance between terminals.
[LH]
[RH]
Cushion (A)
Connector
Resistanc
(± 10%)
1-4
4.13 Ω
Performance of heater is the average temperature of seat surface.
The temperature of seat surface according to pushing the seat heater switch is as below.
First row seat
Cushion
(±2°C/±35.6°F)
Back
(±2°C/±35.6°F)
Type
1st
2nd
3rd
HI-Low
38°C
(100°F)
42°C
(107.6°F)
-
3 Step
36°C
(96.8°F)
39°C
(102.2°F)
42°C
(107.6°F)
HI-Low
45°C
(113°F)
50°C
(122°F)
-
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3 Step
Second row seat
Body Electrical System
Components
Body Electrical System
Circuit Diagram
Cushion
(±2°C/±35.6°F)
HI-Low
40°C
(104°F)
45°C
(113°F)
50°C
(122°F)
38°C
(100.4°F)
42°C
(107.6°F)
-
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Body Electrical System
Inspection
Front Seat
1. Check for continuity and measure the resistance between terminals.
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Resistanc
(± 10%)
Connector
Cushion (C)
1-4
4.54 Ω
Back (B)
1-4
5.16 Ω
Set (A)
3-4
9.70 Ω
Performance of heater is the average temperature of seat surface.
The temperature of seat surface according to pushing the seat heater switch is as below.
Type
First row seat
Cushion
(±2°C/±35.6°F)
Back
(±2°C/±35.6°F)
Body Electrical System
Component Location
3 Step
1st
2nd
3rd
36°C
(96.8°F)
39°C
(102.2°F)
42°C
(107.6°F)
40°C
(104°F)
45°C
(113°F)
50°C
(122°F)
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1. Seat back blower
2. Seat cushion blower
Body Electrical System
Circuit Diagram
3. Air ventilation seat control unit
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Body Electrical System
Description
The ventilated seat system uses a Push method to cool the seat. A blower mounted in the seat generates the cool air, which then travels
through ducts to the seat back and cushion.
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1. Make sure not to spoil drink or water on the seat when equipping with ventilation system seat
2. Because of inhaling the slight air, it is difficult to feel the air strength by the sense of touch.
Body Electrical System
Removal
Cushion Blower
1. Remove the front seat assembly.
(Refer to Body - "Front Seat Assembly")
2. Remove the cushion blower (B) after loosening the screws and disconnecting the connector (A).
Back Blower
1. Remove the front seat assembly.
(Refer to Body - "Front Seat Assembly")
2. Remove the front seat back cover.
(Refer to Body - "Front Seat Back Cover")
3. Disconnect the connector (A) and fastners (B).
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4. Remove the back blower (A) after loosening the mounting screws.
Air Ventilation Unit
1. Remove the front seat assembly.
(Refer to Body - "Front Seat Assembly")
2. Remove the air ventilation unit (A) after loosening the screws and disconnecting the connector.
[Drive's Side]
[Passenger's Side]
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Installation
Cushion Blower
1. Install the cushion blower.
2. Install the front seat assembly.
Back Blower
1. Install the back blower.
2. Install the front seat back cover.
3. Install the front seat assembly.
Air Ventilation Unit
1. Install the air ventilation unit.
2. Install the front seat assembly.
Body Electrical System
Specification
Smart Key Unit
Items
Rated voltage
Operating voltage
Operating temperature
Dark current
Frequency
Specification
DC 12V
DC 9 ~ 16V
-30°C ~ 75°C (-22°F ~ 167°F)
Max. 4mA (When welcome light function off)
433 Mhz
Smart Key FOB
Items
Battery
Distance
Specification
Lithium battery 3V 1EA
30m
More than 2 years
Battery life
Push buttons
An inappropriately disposed battery can be harmful to the environment and human
health.
Dispose the battery according to your local law(s) or regulation.
4 (Door lock / unlock, Trunk lid, Panic)
Frequency(Rx)
134.2 kHz
Frequency(Tx)
433.92 MHz
Numbers
2EA
Antenna
Items
Rated voltage
Operating voltage
Specification
DC 12V
DC 9 ~ 16V
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Operating temperature
Frequency
Numbers
-30°C ~ 80°C (-22°F ~ 176°F)
134.2 kHz
Interior(1EA), Door(2EA), Trunk(1EA), Bumper(1EA)
Body Electrical System
Component Location (1)
1. Smart key unit
2. External buzzer
Component Location (2)
3. Door outside handle
4. Interior antenna 1
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1. Bumper antenna
2. Interior antenna 2
3. Trunk lid open switch
Body Electrical System
Description
The SMART KEY system is a system that allows the user to access and operate a vehicle in a very convenient way. To access the vehicle,
no traditional key or remote control unit is needed.
The user carries a SMART KEY FOB which does not require any conscious actions by the user (e.g. operate a RKE button). The SMART
KEY system is triggered by pressing a push button in the door handle.
After being triggered the vehicle sends out a request in a limited range. If the SMART KEY FOB receives this request, it automatically sends
a response to the vehicle. Then the system decides whether to perform a particular action (unlocking, locking…) or remain inactive.
Again, a communication between the vehicle and the SMART KEY FOB is needed before any actions will be performed.
The System offers the following features :
• Passive unlock via door driver side and passenger side
• Passive locking via door driver side and passenger side
• Passive start
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• Passive access trunk via the trunk lid switch at the trunk
• Passive locking via tailgate
• Max. 2 fobs can be handled by the system
• Immobilizer backup antenna integrated into SSB for TP authentication (i.e. limp home mode)
• Communication with engine management system
• LF-RF communication
1. Passive unlock
The system allows the user to access (unlock) the vehicle without performing any actions with the SMART KEY FOB. This feature could
be different depending on platform as follows:
A. Pressing Push button in door handle
2. Passive locking
The system allows the user to lock the vehicle by pushing a button on door handle with the SMART KEY FOB.
3. Button start
The system allows to switch the power modes (Off, Accessory, Ignition), as well as to start and stop the vehicle’s engine without
performing any actions with the SMART KEY FOB. See Button Engine Start system specification.
4. LIMP HOME Mode
Additionally, the system offers so called “limp home mode”, which is the user can operate all vehicle functions by pushing the key into the
SSB.
Smart Key ECU (SMK ECU)
The SMK ECU manages all functions related to “Passive Unlock”, “Passive Lock” and “Passive Authorization for Engine Start Operation”.
It reads the inputs (Push button in door handle, Start Stop Button (SSB), PARK position Switch), controls the outputs (e.g. exterior and
interior antennas), and communicates via the CAN (depends on the vehicle) as well as a single line interface to further devices of the car.
For communication with the SMART KEY FOB, SMK ECU generates a request (challenge) as an encoded and modulated 134.2 kHz signal
at the inductive antenna outputs and receives the SMART KEY FOB’s response via the external RF receiver.
The main functional blocks of the SMK ECU are:
• Power supply
• Microcontroller with FLASH Memory
• Single Line Interface to EMS
• Input stage
• LF antenna amplifier/driver
• CAN communication with BCM
The LF antenna amplifier/driver generates a 134.2 kHz sinusoidal carrier signal which is distributed to the different antennas.
Smart Key FOB
The system supports up to 2 SMART KEY FOBs.
The main functions of the SMART KEY FOB are:
• Passive functionality: receives LF-challenge and sends automatically RF response.
• Classic RKE function by action up to 3 push buttons.
• Transponder-functionality in case of a flat battery or a disturbed communication.
• LED for operation feedback and battery monitoring.
The FOB's LED indicator may continue to light even with a low transmitter battery.
If the performance or range of the FOB is less than expected, check the transmitter battery.
Antennas
1. Emitting LF Antennas:
Inductive antennas in and at the vehicle are used to transform the current, driven by the SMK ECU antenna driver, into a 134.2 kHz
magnetic field, which is the carrier for the SMART KEY challenge.
Three antennas cover the vehicle’s exterior: two antennas in the Door Handles (DS and PS) cover the area around the doors; one
antenna in the rear bumper covers the area around the trunk.
Up to two antennas cover the vehicle’s interior and the trunk interior: one in the passenger compartment and one in the trunk.
2. Bidirectional Immobilizer Antenna (for Limp Home):
The Immobilizer Backup Antenna is used for sending and receiving data: it emits a magnetic field (134.2 kHz challenge) and receives
changes in the field strength (response of Transponder).
Door Handle
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The front door handles of the two doors (driver door / passenger door) are equipped with emitting LF-antennas to emit the 134.2 kHz signals.
The front door handles are also equipped with a push button.
Push Button
The push button in door handle serves as a trigger to indicate the user’s intent to unlock or lock the vehicle.
The push buttons are installed at front doors, integrated into the door handles.
Another button is installed at the trunk lid.
Operation
Passive Functions
The system allows the user to access the vehicle without having to perform any actions (e.g. RKE button pressing) with the SMART KEY
FOB. It is sufficient that a valid SMART KEY FOB is located within a defined and limited range with respect to the vehicle. So the system is
capable of detecting and authenticating a SMART KEY FOB in the ranges as specified below.
Operating Range
The SMART KEY FOB receives and interprets a challenge sent from the vehicle via the exterior antennas in a free space range of min. 0.7m
measured around the exterior antennas which are integrated in the door handles. The trunk access range is also min. 0.7m measured from
the antenna position.
Passive Access (Passive Entry)
Pressing one of the push buttons in the door handles when all doors locked indicates the operator’s intent to access the vehicle and thus
triggers the system for unlock
Passive Locking (Exit)
Pressing one of the push buttons in the door handles when one of the following condition is fulfilled:
• All door is closed and at least one door is unlocked.
indicates the operator’s intent to lock the vehicle and thus triggers the system for a lock.
Passive Open Trunk
Pressing the Trunk Lid Switch when trunk is closed indicates the operator’s intent to open the trunk and thus triggers the system.
Subsequently, the SMK ECU sends a LF-challenge to the SMART KEY FOB via the exterior bumper antenna. The SMART KEY FOB
answers with a RF-response. If the received response matches the expected answer, SMK ECU sends a “trunk open” message via the CAN
network.
Passive Trunk Warning
Whenever the trunk is closed, SMK ECU uses a suitable search strategy to avoid trunk buzzer warning by a fob inside the vehicle. Then
SMK searches for a SMART KEY FOB in the interior of the trunk. If a valid SMART KEY FOB is found in the trunk, the SMK ECU activates
SMK external buzzer (TBD) to inform the user that the trunk has been closed with a fob inside the trunk.
SMK will send the trunk open command to BCM for trunk reopening if trunk reopening bit is set(BK)For this functionality, a “valid” SMART
KEY FOB means any SMART KEY FOB that belongs to the vehicle, even if it’s DEACTIVATED.
- A blind spot in the trunk similar to any RF disturbance may lead to no trunk warning. Due to the penetration of the bumper antenna
into the trunk area the lid may open without an Identification Device outside.
Smart Key Reminder 1
1. Preconditions:
All terminals OFF & at least one door open & locking status is not locked checked by SMK periodically every 100ms, as long as CAN/LIN
active.
2. Event:
At least 1 door knob status changed from unlock to lock.
3. SMK actions:
A. IF NO FOB-IN ACTIVE
SMK performs a search for the fobs in the interior of the vehicle. The same LF-strategy has to be used as it is defined for the ID out
warning (registering only, no authentication)
B. IF FOB-IN ACTIVE
SMK searches valid TP
If no fob or no TP has been found, no action is required.
If any valid fob or valid TP has been found, SMK unlocks the vehicle by sending a CAN Key Reminder unlock message with the fob
number.
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If any valid fob has been found, SMK unlocks the vehicle by sending a CAN/LIN Key Reminder unlock message with the fob number.
Smart Key Reminder 2
1. Preconditions:
All terminals OFF & any door (including trunk) open & no FOB-IN & no locking status (checked by SMK periodically every 100ms, as long
as CAN/LIN active)
2. Vehicle action:
Closing last door or trunk with knobs locked state, or with a locking in progress
3. SMK actions:
Before elapsing 500ms after the closing if all doors are locked then:
A. IF NO FOB-IN ACTIVE
SMK performs a search for the fobs in the interior of the vehicle.
The same LF-strategy has to be used as it is defined for the ID out warning (registering only, no authentication)
B. IF FOB-IN ACTIVE
SMK searches valid TP
If no fob has been found, no action is required.
If any valid fob or valid TP has been found, SMK sends unlock command via CAN and activates ext. buzzer warning.
If any valid fob has been found, SMK sends unlock command via CAN/LIN and activates ext. buzzer warning.
Smart Key Door Lock Warning
Door Lock Warning 1
1. Preconditions:
While (at least one door knob is unlocked) & (ACC ON or IGN ON) & (No FOB-IN) :
A. (All doors are closed) & (trunk closed)
2. Event:
A. User presses the push button in door handle or trunk
3. SMK actions:
SMK performs a search for the fobs outside of the vehicle; the same LF-strategy has to be used as it is defined for "Scenario Access with
I/O Distinction".
Door Lock Warning 2
1. Preconditions:
Same as passive locking precondition but with at least one door open.
2. Event:
User presses the door handle Push button .
3. SMK actions:
SMK performs a search for the fobs outside of the vehicle; the same LF-strategy has to be used as it is defined for "Scenario Access with
I/O Distinction".
If no fob has been found, no action is required.
If the preconditions are no longer valid during buzzer active time (3 seconds), the SMK ECU stops the buzzer immediately.
Door Lock Warning 3
1. Preconditions:
Same as passive locking precondition
2. User action:
A. User presses the door handle Push button
3. SMK ECU actions:
A. If ATWS(Anti Theft Warning System) is in DISARM status, SMK ECU performs a search for the fob inside of the vehicle (use "Door
Lock Warning 3" scenario)
If no fob has been found, the passive locking is performed.
If any valid fob has been found, SMK ECU activates the external buzzer.
If the activity timer elapsed or ACC ON or IGN1 ON or NOT All door closed or FOB-IN, the SMK ECU stops the buzzer immediately.
After searching of inside fob, SMK ECU also performs a search for fobs outside of the vehicle.
Smart Key Lamp Warning
1. SMK actions:
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As long as the preconditions are valid, the SMK ECU performs a periodical search for the fobs in the interior of the vehicle; the same LFstrategy has to be used as it is defined for the ID out warning (registering only, no authentication); periodical means, the search is done
every 3 seconds.
If no fob has been found, the SMK ECU starts Key out indicator lamp activation as all preconditions are valid and will perform another
search 3 seconds later.
If any valid fob has been found, the SMK ECU stops the Key out indicator lamp and will (if one door is open) perform another search 3
seconds later; if no door is open then it’s only at the next When the preconditions are still valid, the search resumes by opening of one door.
Failsafe Functions (Backup For Limp Home)
In case of a discharged battery of the SMART KEY FOB or disturbed transmission, the following functions are available:
• Unlocking / locking of doors or trunk (or tailgate depending of the vehicle configuration): use of mechanical key
User Information Functions
ID OUT Warning
1. Preconditions:
A. (ACC or IGN1) & (any door open or trunk open)
2. Event:
The last opened door is closed
3. SMK action:
SMK searches for a SMART KEY FOB in the interior.
A. If no valid SMART KEY FOB is found, the SMK activates external buzzer and also sends ID OUT warning via CAN (exterior buzzer
warning and internal buzzer warning).
B. If a door is opened and closed again during terminals on and inside valid fob, SMK re-enables the authentication and stops the
warning. If the terminal is in ACC, SMK shall turn on immobilizer lamp.
If there is a LF error (LF overheating or LF antenna failure), the system will have the same behavior as it is with no fob found.
Immobilizer Lamp
Removing the PIF from the MSL and reinserting the PIF and pushing the MSL Knob will switch the lamp on again.
Fob Battery Low Voltage Detection
To detect fob low battery condition, certain battery voltage measurement and low voltage detection strategy are implemented into fob. The
measurement of the battery voltage will be done if fob button is pressed or if a LF measurement command is received.
If the fob has detected a low battery voltage, the LED will not be switched on at button press.
Learning Description
In this chapter, the learning procedure for SMK, FOBs is described.
For the learning of the SMK, FOBs, it's necessary to have a connection to the diagnostic tool.
Learning MODE
Whatever the mode, the learning procedures are managed by the SMK.
Prior to start learning service, Fob-In signal must be active and the vehicle secret code (called as PIN code) should be known.
Teaching MODE
This mode is used by the dealers in order to replace SMK and/or the set of keys, or to register additional keys for an existing system. That
means the system already has been learnt with certain PIN Code. The PIN Code is fixed for the life time of the vehicle, therefore the same
PIN Code must be used in this mode. Otherwise learning will be failed
Teaching MODE Procedure Description (Step By Step)
Objective: Key teaching procedure at service station
Initial state:
- SMK replacement: SMK is not learnt, SMART FOB are already learnt with same PIN code
- Additional or new keys teaching: SMK is already learnt with same PIN code
Body Electrical System
Inspection
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1. Check that the red light flickers when the door lock or unlock button is pressed on the transmitter.
2. Remove the battery (A) and check voltage if the red light doesn't flicker.
Standard voltage :3V
3. Insert the battery (A) into the tester (09954-2P100).
4.
5.
6.
7.
Push the test button and If "0.00" is displayed on screen, it means that the battery voltage is 2V or less.
If "L" is displayed on screen, it means that the battery is low power and it needs to replace.
To prevent the discharge of electricity, turn the tester power off.
Replace the transmitter battery with a new one, if voltage is low power then try to lock and unlock the doors with the transmitter by
pressing the lock or unlock button five or six times.
8. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, register the transmitter code, then try to lock
and unlock the doors.
9. If the doors lock and unlock, the transmitter is O.K, but if the doors don't lock and unlock, replace the transmitter.
An inappropriately disposed battery can be harmful to the environment and human health.
Dispose the battery according to your local law(s) or regulation.
Smart Key Code Registration (Using GDS)
1. Connect the DLC cable of GDS to the data link connector (16 pins) in driver side crash pad lower panel, turn the power on GDS.
2. Select the vehicle model and then do "CODE SAVING"
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3. After selecting "CODE SAVING" menu, button "ENTER" key, then the screen will be shown as below.
4. After pushing the SSB to "OFF", push "ENTER" key to proceed to the next mode for code saving. Follow steps 1 to 4 and then code
saving is completed.
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Smart Key Code Saving
1. Connect the DLC cable of GDS to the data link connector in driver side crash pad lower panel, turn the power on GDS.
2. Select the vehicle model and then do "Smart key code saving".
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3. After selecting "Smart key teaching" menu, push "Enter" key, then the screen will be shown as below.
4. After pushing the SSB with the teaching key, press "OK" button.
5. Input the "Pin code" for first key teaching.
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6. Confirm the message "First key teaching completed".
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7. Confirm the message "Second key teaching completed".
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8. Then the screen will be shown as below when key teaching process is completed.
Body Electrical System
Component (1)
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Connector Pin Information
No.
Connector A
Connector B
Connector C
1
V_BAT CPU
Assistant side antenna ground
Immobilizer antenna ground
2
V_BAT Load
Assistant side antenna power
Immobilizer antenna power
3
Ignition 1
Driver side antenna ground
-
4
Ignition 2 relay
Driver side antenna power
-
5
Ignition 1 relay
Wheel speed
-
6
-
P position
SSB LED ON
7
-
-
SSB LED ACC
8
EMS COM
C CAN low
SSB illumination power
9
-
C CAN high
-
10
B CAN high
Interior 1 antenna ground
-
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11
B CAN low
Interior 1 antenna power
12
ACC
Bumper antenna ground
-
13
Ignition 2
Bumper antenna power
Stop lamp fuse
14
ACC relay
Interior 2 antenna ground
Brake switch
15
Starter relay
Interior 2 antenna power
-
16
Start feedback
-
Immobilizer indicator
17
ESCL battery
RPM
Exterior buzzer
18
-
-
SSB illumination ground
19
-
SSB switch 2
20
Assistant toggle button
SSB switch 1
21
Driver toggle button
22
-
23
Power ground 2
24
Power ground 1
Body Electrical System
Circuit Diagram
-
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Body Electrical System
Inspection
Smart Key Unit
- Refer to Smart key System - "Smart key Diagnostic"
Smart Key Switch
- Refer to Smart key System - "Smart key Diagnostic"
Antenna
- Refer to Smart key System - "Smart key Diagnostic"
Trunk Lid Open Switch
1. Check for continuity between the trunk lid open switch terminal.
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2. If continuity is not specified, inspect the switch.
Removal
Smart Key Unit
1. Disconnect the negative (-) battery terminal.
2. Remove the main crash pad assembly.
(Refer to Body - "Main Crash Pad Assembly")
3. Loosen the mounting bolts and nut from the smart key unit bracket.
4. Remove the smart key unit (B) after disconnecting the connector (A) from the smart key unit.
Interior Antenna 1
1. Disconnect the negative(-) battery terminal.
2. Remove the floor console assembly.
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(Refer to Body - "Floor Console Assembly")
3. Disconnect the connector (A) from the interior antenna.
4. Remove the interior antenna (A) after loosening the mounting nuts.
Interior Antenna 2
1. Disconnect the negative (-) battery terminal.
2. Disconnect the connector (A) from the interior antenna 2.
3. Remove the interior antenna 2 (B) after loosening the mounting nuts.
When removing the interior antenna 2, the rear seat back assembly does not need removal.
Exterior Bumper Antenna
1. Disconnect the negative(-) battery terminal.
2. Remove the rear bumper cover.
(Refer to Body - "Rear Bumper Cover")
3. Disconnect the connector (A), then remove the rear bumper antenna (B) with loosening the mounting screws.
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Buzzer
1. Disconnect the negative(-) battery terminal.
2. Remove the front left wheel guard.
3. Remove the buzzer (B) after disconnecting the connector (A).
Door Outside Handle
1. Disconnect the negative (-) battery terminal.
2. Remove the front door module.
(Refer to Front Door - "Front Door Module")
3. Remove the hole plug (A).
4. After loosening the mounting bolt, then remove the front door outside handle cover (B).
5. Remove the front door outside handle (A) by sliding it rearward.
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Tailgate Open Switch
1. Disconnect the negative (-) battery terminal.
2. Remove the tailgate trim.
(Refer to Body - "Tail Gate Trim")
3. Disconnect the tailgate open switch connector (A).
4. Remove the tailgate switch (A).
Installation
Smart Key Unit
1.
2.
3.
4.
Install the smart key unit.
Connect the connector and install the smart key unit.
Install the main crash pad assembly.
Install the negative (-) battery terminal and check the smart key system.
Interior Antenna 1
1. Install the interior antenna.
2. Install the floor console assembly.
3. Install the negative (-) battery terminal and check the smart key system.
Interior Antenna 2
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1. Install the interior antenna 2.
2. Install the rear seat cushion assembly.
3. Install the negative (-) battery terminal and check the smart key system.
Exterior Bumper Antenna
1. Install the exterior bumper antenna.
2. Install the rear bumper cover.
3. Install the negative (-) battery terminal and check the smart key system.
Buzzer
1. Install the buzzer.
2. Install the front left wheel guard.
3. Install the negative (-) battery terminal and check the smart key system.
Door Outside Handle
1. Install the door outside handle.
2. Install the door trim.
3. Install the negative (-) battery terminal and check the smart key system.
Tailgate Open Switch
1. Install the tailgate open switch.
2. Install the tailgate trim.
3. Install the negative (-) battery terminal and check the smart key system.
Body Electrical System
Inspection
Self Diagnosis With GDS
Smart key system defects can be quickly diagnosed with the GDS. GDS operates actuator quickly to monitor, input/output value and self
diagnosis.
The following three features will be major problem in SMART KEY system.
1. Problem in SMART KEY unit input.
2. Problem in SMART KEY unit.
3. Problem in SMART KEY unit output.
The following three diagnostic solutions will be the main solution process to a majority of concerns.
1. SMART KEY unit Input problem : switch diagnosis
2. SMART KEY unit problem : communication diagnosis
3. SMART KEY unit Output problem : antenna and switch output diagnosis
Switch Diagnosis
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel, turn the power on GDS.
2. Select the vehicle model and then SMART KEY system.
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3. Select the "SMART KEY unit".
4. After IG ON, select the "Current data".
5. You can see the situation of each switch on scanner after connecting the "current data" process.
Display
FL Toggle switch
FR Toggle switch
Trunk switch
Gear P Position
IGN 1
ACC
Push Knob switch
External Buzzer
Description
ON : Push button is ON in the driver door handle.
ON : Push button is ON in the assist door handle.
ON : Trunk button is ON.
ON : Shift lever is P position.
ON : IGN switch is IG position.
ON : IGN switch is ACC position.
ON : Push knob switch is ON.
ON : Buzzer is ON.
Communication Diagnosis With GDS (Self Diagnosis)
1. Communication diagnosis checks that the each components operates normal.
2. Connect the cable of GDS to the data link connector in driver side crash pad lower panel.
3. After IG ON, select the "DTC".
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Antenna Actuation Diagnosis
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel.
2. After IG ON, select the "ACTUATION TEST".
3. Set the smart key near the related antenna and operate it with a GDS.
4. If the LED of smart key is blinking, the smart key is normal.
5. If the LED of smart key is not blinking, check the voltage of smart key battery.
6. Antenna actuation
A. INTERIOR Antenna
B. Trunk antenna
C. BUMPER/Antenna
D. DRV_DR Antenna
E. AST_DR Antenna
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Antenna Status Check
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel.
2. Select the "Antenna Status Check".
3. After IG ON, select the "Antenna Status Check".
4. Set the smart key near the related antenna and operate it with a GDS.
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5. If the smart key runs normal , the related antenna, smart key(transmission, reception) and exterior receiver are normal.
6. Antenna status
A. INTERIOR Antenna
B. Trunk antenna
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C. BUMPER/Antenna
D. DRV_DR Antenna
E. AST_DR Antenna
Serial Communication Status Check
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel.
2. Select the "Serial Communication Line Check".
3. After IGN ON, select the "Receiver Communication Line Check".
4. Check the serial communication line with a GDS.
5. If the smart key runs normal, the communication of smart key unit, exterior receiver are normal.
6. If the smart key runs abnormal, check the following items.
A. Disconnection or no response of the exterior receiver communication line.
B. The exterior receiver communication line disconnection and ground connection.
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Interior Antenna Actuation Check
1. Set the smart key in the following shade area and check the IG ON.
2. If the ignition is ON, the antenna runs normal.
3. Check the interior antenna ignition mode.
4. Set the smart key in the following shade area and actuate the antenna. Check the LED of smart key is blinking.
5. If the LED of smart key is not blinking, check the antenna in shade area.
FOB Status Check
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel.
2. After IGN ON, select the "FOB KEY STATUS INFORMATION".
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Smart Key Status Check
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel.
2. After IGN ON, select the "SMK STATUS INFORMATION".
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Neutralization Status Check
1. Connect the cable of GDS to the data link connector in driver side crash pad lower panel.
2. After IGN ON, select the "Neutralization mode".
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Input Signal List
No.
Item name
Unit
1
SSB SW1
-
2
SSB SW2
-
3
ACC
-
4
IGN1
-
5
IGN2
-
6
Gear 'P' Position (A/T)
Clutch SW (M/T)
-
7
Brake SW
8
FL Door Lock Button
-
9
FR Door Lock Button
-
10
Battery Voltage
-
11
Wheel Speed
-
12
RPM
-
13
Stop Lamp Fuse
-
14
Start Feed Back
-
Actuator List
No.
Item name
Condition
1
Immobilizer indicator Lamp (Cluster)
Ignition switch ON
Engine off
2
External Buzzer
Ignition switch ON
Engine off
3
Interior Antenna Active
Ignition switch ON
Engine off
6
Bumper/trunk Antenna Active
Ignition switch ON
Engine off
7
DRV_DR Antenna Active
Ignition switch ON
Engine off
8
AST_DR Antenna Active
Ignition switch ON
Engine off
9
SSB Illumination (OFF/ACC/ON)
Ignition switch ON
Engine off
10
ACC/IGN1/IGN2 Relay
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Ignition switch ON
Engine off
Body Electrical System
Component Location
1. Virtual engine sound system unit
2. Virtual engine sound speaker
Body Electrical System
Description
The VESS (Virtual engine sound system) generates engine sound when you start the hybrid system.
This sound is for pedestrians to hear vehicle sound because there is no engine sound in hybrid driving.
VESS operates when vehicle speed is between 0~20km/h (0~12mph)
Body Electrical System
Component Location
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Body Electrical System
Circuit Diagram
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Body Electrical System
Removal
1. Disconnect the negative(-) battery terminal.
2. Remove the AVN head unit.
(Refer to Body Electrical System - "AVN System")
3. Disconnect the VESS unit connector (A).
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4. Remove VESS unit (A) after loosening the mounting nut and screw.
Installation
1. Install the VESS unit and connect the connector.
2. Install the AVN head unit.
3. Connect the negative(-) battery terminal.
Body Electrical System
Component Location
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Body Electrical System
Removal
1. Disconnect the negative(-) battery terminal.
2. Remove the front wheel guard.
(Refer to Body - "Front Bumper")
3. Disconnect the VESS connector (A).
4. Remove the VESS speaker (A) after loosening the mounting bolts.
Installation
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1. Install the VESS speaker and connector.
2. Install the front wheel guard.
3. Connect the negative (-) battery terminal.
Body Electrical System
Component Location
1. Windshield wiper arm & blade
2. Wiper & washer switch
3. Windshield washer hose
4. Windshield wiper motor & linkage
5. Washer motor
6. Washer reservoir
7. Wiper relay (Engine room relay box)
Body Electrical System
Inspection
Check for continuity between the terminals while operating the wiper and washer switch. If it is not normal condition, replace wiper and wiper
switch.
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Wiper Switch
Washer Switch
Removal
1. Remove the steering column shroud lower / upper panel.
(Refer to Body - "Steering Column Shroud Panel")
2. Disconnect the connector (A).
3. If necessary of removing the wiper & washer switch (A), release the lock of wiper switch using tool without removing the steering wheel
and the clock spring.
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4. Remove the steering wheel.
(Refer to Steering System - "Steering Wheel")
5. Remove the clock spring.
(Refer to Restraint - "Driver Airbag (DAB) Module and Clock Spring")
6. Remove the multifunction switch assembly (A) after loosening 2 screws.
Installation
1.
2.
3.
4.
Install the multifunction switch after connecting the connector.
Install the clock spring and steering.
Install the upper and lower shroud.
Install the steering wheel.
Body Electrical System
Component Location
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1. Cap
2. Nut
3. Wiper arm & blade
4. Rivet
5. Cowl top cover
6. Bolt
7. Wiper motor & linkage assembly
Body Electrical System
Removal
1. Loosen the windshield wiper arm nut (B) after removing a wiper cap (A).
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2. Remove the windshield wiper arm and blade.
3. If necessary, release the wiper blade fixing clip by pulling up and remove the wiper blade from the inside radius of wiper arm.
4. Disconnect the washer hose (A) connected to cowl top cover.
5. Remove the weather strip and the cowl top cover (A) after removing 5 rivets.
6. Remove the windshield wiper motor and linkage assembly (A) after removing 2 bolts.
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7. Disconnect the wiper motor connector (A) from the wiper motor & linkage assembly.
8. Hold the wiper motor crank arm and remove the upper linkage (A) from the wiper motor crank arm.
9. Remove the lower linkage (A) from the wiper motor crank arm.
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10. Hold the arm to use the plyer, remove the crank arm (A) after loosening the mounting nut.
Before removing the wiper motor and linkage assembly, make sure that the linkage is stopped at auto stop position.
To install the wiper motor crank arm exactly, check that the linkage is aligned with the crank arm in straight line and the angle of
each linkages.
Be careful not to bend the linkage.
11. Remove the wiper motor (A) after loosening the mounting bolts.
Be careful not to miss the mounting nuts.
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Installation
1. Install the wiper motor.
2. Install the crank arm.
To install the wiper motor crank arm, make sure that the linkage is aligned with the crank arm in straight line and set the angle of
each linkages exactly.
3. Install the lower and upper linkage to the wiper motor crank arm.
To install the wiper motor crank arm, make sure that the linkage is aligned with the crank arm in straight line and set the angle of
each linkages exactly.
Be careful not to bend the linkage.
4. Install the wiper motor and linkage assembly and then connect the wiper motor connector.
Tightening torque:
6.9 ~ 10.8Nm (0.7 ~ 1.1, kgf.m, 5.0 ~ 7.9 lb-ft)
5. Install the cowl top cover.
6. Install the windshield wiper arm and blade.
Tightening torque:
22.6 ~ 26.5 Nm (2.3 ~ 2.7 kgf.m, 16.6 ~ 19.5 lb-ft)
- The windshield wiper motor must be cycled to make sure that it is in the auto stop position.
If necessary, adjust the wiper arm and blade.
7. Install the wiper arm and blade to the auto stop position.
A : Auto stop position (Blade)
Inspection
Speed Operation Check
1. Disconnect the connector (A) from the wiper motor.
2. Attach the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 5.
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3. Check that the motor operates at low or high speed as below table.
Common sources of contamination are insects, tree sap, and hot wax treatments used by some commercial car washes. If the
blades are not wiping properly, clean both the window and the blades with a good cleaner or mild detergent, and rinse thoroughly
with clean water.
Body Electrical System
Inspection
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
Before filling the reservoir tank with water, check the filter for foreign material or contamination. if necessary, clean the filter.
2. Connect positive (+) battery cables to terminal 1 and negative (-) battery cables to terminal 2 respectively.
3. Check that the motor operates normally and the washer motor runs and water sprays from the front nozzles.
4. If they are abnormal, replace the washer motor.
Washer Fluid Level Sensor Switch
1. Disconnect the negative(-) battery terminal.
2. Drain the washer fluid less than 600 cc.
3. Check for continuity between the No. 1 and No.2 terminal in each float position.
There should be continuity when the float is down.
There should be no continuity when the float is up.
4. If the continuity is not as specified, replace the washer fluid level switch
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Removal
- When servicing the washer pump, be careful not to damage the washer pump seal.
- Do not operate the washer pump before filling the washer reservoir.
Failure to do so could result in premature pump failure.
1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
3. Disconnect the washer motor connector (A) after removing the washer hose from the motor.
4. Remove the reservoir (A) after loosening 2 bolts.
Installation
1. Reassemble the washer reservoir.
Tightening torque:
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6.9 ~ 10.8Nm (0.7 ~ 1.1, kgf.m, 5.0 ~ 7.9 lb-ft)
Before installing the pump motor, check the filter for foreign material or contamination. if necessary, clean the filter into the pump
motor.
2. Connect the washer motor connector and washer hose.
3. Reassemble the front bumper cover.
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Heating,Ventilation, Air Conditioning
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 7feet(2m) or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 7feet(2m) or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 7feet(2m) or farther away from the vehicle to prevent unintended engine start.
(This is to prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Heating,Ventilation, Air Conditioning
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Heating,Ventilation, Air Conditioning
Specification
Air Conditioner
Item
Compressor
Specification
Type
ESC33n (Electric Scroll)
Communication type
CAN communication
Oil type & Capacity
POE OIL, 180±10g
Motor type
BLDC
Rated voltage
360V
Operation voltage
240~413V
Displacement
33cc/rev
Condensor
Heat rejection
13,400 -3% kcal/hr
Air pressure transducer
Pressure value
Voltage=0.00878835*Pressure(psig)+0.5
Page 10 sur 127
Expansion valve
Type
Block type
Type
Refrigerant
R-134a
Capacity
Without heat pump
550±25g (19.4±0.88 oz.)
With heat pump
900±25g (31.7±0.88 oz.)
Heater And Evaporator Unit
Item
PTC Heater
Specification
Type
Fin & Tube type
Operating voltage
DC 240V ~ 420V
Heating capacity
Exterior Condensor
Heating capacity
Interior Condensor
Heat Pump
Evaporator
4,700 ± 5% kcal/hr
17,000 - 3% kcal/hr
2,600 - 5% kcal/hr
Chiller
770g
Accumulator
950cc
Mode operating type
Actuator
Temperature operating type
Actuator
Temperature contorl type
Evaporator temperature sensor
A/C ON/OFF
ON : 2.3±0.5°C, OFF : 0.6±0.5°C
Heating capacity
4,700 - 5% kcal/hr
Heating,Ventilation, Air Conditioning
Special Service Tools
Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• When removing, installing or inspecting the high voltage
battery terminals or wiring where spark may occur.
• When working on the high voltage battery pack assembly.
Page 11 sur 127
Face shield
Removed high voltage components are placed on the
insulation mat to prevent safety accidents.
Insulation mat
High voltage components are covered with insulation sheet to
protect people not wearing personal protective equipment from
safety accidents.
Insulation sheet
Heating,Ventilation, Air Conditioning
Troubleshooting
Problem Symptoms Table
Before replacing or repairing air conditioning components, first determine if the malfunction is due to lack of refrigerant, air flow or
compressor.
Use the following table to find the cause of the problem. The numbers indicate the order of the likely cause of the problem. Check each part
in order. If necessary, replace the corresponding parts.
After fixing the area of malfunction, check the complete system to ensure satisfactory performance.
Standard :
Symptom
Suspected Area
1. Blower fuse
2. Blower motor
No blower operation
3. PWM blower module
4. Blower speed control switch
5. Wire harness
No air temperature control
1. Engine coolant capacity
2. Heater control assembly
1. Refrigerant capacity
2. A/C fuse
3. Limiter clutch
No compressor operation
4. Compressor
5. A/C pressure transducer
6. A/C switch
7. Evaporator temperature sensor
8. Wire harness
Vented air not cold
1. Refrigerant capacity
2. Refrigerant pressure
3. Drive belt
4. Limiter clutch
Page 12 sur 127
5. Compressor
6. A/C pressure transducer
7. Evaporator temperature sensor
8. A/C switch
9. Heater control assembly
10. Wire harness
1. Refrigerant capacity
2. Drive belt
3. Limiter clutch
4. Compressor
Insufficient cooling
5. Condenser
6. Expansion valve
7. Evaporator
8. Refrigerant lines
9. A/C pressure transducer
10. Heater control assembly
No engine idle-up when A/C switch ON
1. MCU
2. Wire harness
No air inlet control
1. Heater control assembly
No mode control
1. Heater control assembly
1. Cooling fan fuse
No cooling fan operation
2. Fan motor
3. Engine ECM
4. Wire harness
Heating,Ventilation, Air Conditioning
Instructions
When Handling Refrigerant
1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling the
refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the refrigerant splashes into
your eyes, wash off immediately with clean water.
3. The R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature is below 52°C (126°F).
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-134a, upon coming into
contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended lubricant for R-134a systems. If lubricants other than the recommended type are used, system failure may occur.
6. POE lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be observed:
A. When removing refrigerant components from a vehicle, cap the components immediately to prevent entry of moisture.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking on moisture.
D. Use the recommended lubricant from a sealed container only.
7. Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
8. Since the electric compressor uses high-voltage, you should use POE oil which have high volumetric resistivity.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
9. If an accidental discharging occurs in the system, ventilate the work area before resuming the service.
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When replacing parts ON A/C system
1.
2.
3.
4.
Never open or loosen a connection before the system has been discharged.
Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
Do not remove the sealing caps from a Replacement component until it is ready to be installed.
Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil before making the
connection.
When Installing Connecting Parts
Flange With Guide Pin
Check new O-ring for any damage (use only the specified) and lubricate with compressor oil. Tighten the nut to specified torque.
• T stands for tensile intensity and is stamped on the head of each bolt in numerals.
Handling tubing and fittings
The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free refrigerant and
refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and cause problems or serious damage.
The Following precautions must be observed
1. When the refrigeration system needs to be opened, have everything you will need to service the system ready so the system will not be
left open any longer than it is necessary.
Page 14 sur 127
2.
3.
4.
5.
Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
All lines and components in parts stock should be capped or sealed until they are ready to be used.
Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean and dry.
Heating,Ventilation, Air Conditioning
Refrigeration Cycle
Heating,Ventilation, Air Conditioning
Refrigerant System Service Basics
• Since the electric compressor uses high-voltage, POE oil with high volumetric resistivity should be used.
• Do not use the same A/C recovery / charging station as in conventional belt-driven compressors.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the A/C
compressor may not work.
Refrigerant Recovery
Use only U.L.-listed service equipment that is certified to meet the requirements of SAE J2210 when removing HFC-134a (R-134a) from the
air conditioning system.
• Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
• Be careful when connecting service equipment.
• Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming to service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect an R-134a refrigerant
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following
the equipment manufacturer's instructions.
[Without Heat Pump]
[With Heat Pump]
Page 15 sur 127
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to install the same
amount of new refrigerant oil back into the A/C system before charging.
System Evacuation
Use only U.L.-listed service equipment that is certified to meet the requirements of SAE J2210 when removing HFC-134a (R-134a) from the
air conditioning system.
• Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
• Be careful when connecting service equipment.
• Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming to service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using an R-134a
refrigerant Recovery/Recycling/Charging System. (If the system has been open for several days, the receiver/dryer should be replaced,
and the system should be evacuated for several hours.)
2. Connect an R-134a refrigerant
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following
the equipment manufacturer's instructions.
3. If the pressure does not reach over 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there may be a leakage in the system. Partially
charge the system and check for any leakages (see Leak Test).
4. Remove the low pressure valve from the low-pressure service port.
System Charging
Page 16 sur 127
Use only U.L.-listed service equipment that is certified to meet the requirements of SAE J2210 when removing HFC-134a (R-134a) from the
air conditioning system.
• Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
• Be careful when connecting service equipment.
• Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming to service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect an R-134a refrigerant
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) as shown, following the equipment manufacturer's
instructions.
2. Add the same amount of new refrigerant oil to system that was removed during recovery. Use only specified refrigerant oil. Charge the
system with R-134a refrigerant. Do not overcharge the system as it may damage the compressor.
Specified amount
Without heat pump : 550 ± 25g (19.4 ± 0.88 oz.)
With heat pump : 900 ± 25g (31.7 ± 0.88 oz.)
Refrigerant Leak Test
Always conduct a leak test with an electronic leak detector whenever leakage of refrigerant is suspected and when conducting service
operations that accompany disassembling, loosening or connecting of fittings.
• In order to use the leak detector properly, read the manual supplied by the manufacturer.
If a gas leak is detected, proceed as follows:
1. Check the tightening torque of the connection fittings, and if it is too loose, tighten to the proper torque. Using a leak detector (A), check
for gas leakage.
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the fittings, and
check their seating faces for damage. Replace at all times even for a slight damage.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
Heating,Ventilation, Air Conditioning
Component Location Index
Engine Room
Page 17 sur 127
[Without Heat Pump]
1. Receiver-drier
2. Condensor
3. A/C Pressure Transducer (APT)
4. Service port (Low pressure)
5. Service port (High pressure)
[With Heat Pump]
6. Suction & Liquid tube
7. Expansion valve
8. Suction pipe
9. Suction hose
10. Electric A/C compressor
Page 18 sur 127
1. Electric A/C compressor
2. Receiver-drier
3. Exterior condensor
4. Refrigerant temperature sensor #1
5. Chiller
Interior
6. 3 ways solenoid valve assembly
7. Accumulator
8. 2 ways solenoid valve assembly
9. Refrigerant temperature sensor #2
10. Expansion valve
Page 19 sur 127
1. Photo sensor
2. Heater & Blower unit
3. Evaporator temperature sensor
4. Heater & A/C control unit
Heating,Ventilation, Air Conditioning
Oil Specification
1. The HFC-134a system requires synthetic compressor oil (POE) whereas the R-12 system requires mineral compressor oil. The two oils
must never be mixed.
2. Compressor oil (POE) varies according to compressor model. Be sure to use oil specified for the model of compressor.
A. Since the electric compressor uses high-voltage, POE oil with high volumetric resistivity should be used.
B. Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
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• If the POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric resistivity can occur
and inoperative A/C compressor may result, A/C compressor may not work.
• If the POE oil gets mixed with PAG oil, replace the compressor with new one and clean inside the A/C system (condenser,
refrigerant line, evaporator and etc.)
Handling of Oil
1. The oil should be free from moisture, dust, metal powder, etc.
2. Do not mix with other oil.
3. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC-134a and R-1234yf
compressor oils are prone to absorb moisture.)
4. The compressor oil must be stored in steel containers, not in plastic containers.
Compressor Oil Check
The oil used to lubricate the compressor is circulating with the refrigerant.
Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil.
Total volume of oil in system
POE OIL : 180 ±10cc (6.1 ± 0.3 oz.)
Oil Recovery Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of oil in the system or
replacing any components of the system, the compressor must be running in advance of oil recovery operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine, turn the air conditioning switch "ON" and set the blower motor control knob to its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4. Stop the engine.
Heating,Ventilation, Air Conditioning
Component Location
[Without Heat Pump]
Page 21 sur 127
1. Refrigerant line
[With Heat Pump]
Page 22 sur 127
1. Refrigerant line
Heating,Ventilation, Air Conditioning
Replacement
1. Discharge refrigerant from refrigeration system.
2. Replace faulty tube or hose.
• Cap the open fittings immediately to keep moisture or dirt out of the system.
3. Tighten joint of bolt or nut to specified torque.
• Connections should not be tightened to over the specified torque.
Items
Compressor
N.m
kgf.m
lb-ft
20.0 ~ 33.0
2.0 ~ 3.4
14.8 ~ 24.3
Page 23 sur 127
Accumulator mounting bolt
Discharge hose mounting bolt
Discharge pipe mounting bolt
6.9 ~ 10.8
0.7 ~ 1.1
5.1 ~ 8.0
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Refrigerant valve
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Chiller (Refrigerant line)
5.9 ~ 9.8
0.6 ~ 1.0
4.3 ~ 7.2
Suction pipe mounting bolt
Suction hose mounting bolt
Tube & Hose assembly mounting bolt
Accumulator nut
Discharge hose nut
Discharge pipe nut
Suction pipe nut
Suction hose nut
Tube & Hose assembly nut
4. Evacuate air in the refrigeration system and charge system with refrigerant.
Specified amount
Without heat pump : 550 ± 25g (19.4 ± 0.88 oz.)
With heat pump : 900 ± 25g (31.7 ± 0.88 oz.)
5. Inspect for leakage of refrigerant.
Using a gas leak detector, check for leakage of refrigerant.
6. Inspect A/C operation.
Heating,Ventilation, Air Conditioning
Specification
Model
ESC33n
Motor
BLDC Motor
Control Type
CAN
Compression Type
Scroll
Capacity
33cc/rev
Operating Voltage Range
190~320V
Rated Voltage
288V
Mount Type
Bracket Mounting, 4 Point Mounting
Heating,Ventilation, Air Conditioning
Components Location
[Without Heat Pump]
Page 24 sur 127
1. Electric A/C compressor
[With Heat Pump]
Page 25 sur 127
1. Electric A/C compressor
Components
Page 26 sur 127
1. Control Part
2. Motor Part
3. Compression Part
Heating,Ventilation, Air Conditioning
Description
Electric compressors improve the fuel efficiency and operates the air conditioner even when the engine has stopped.
Operation Principle
Compression Part
One of the scrolls is fixed while the other orbits eccentrically without self-rotating, thereby to trap and pump refrigerant in the pockets
between the scrolls.
Page 27 sur 127
Motor Part
Converts electric power into a mechanical motion with Brushless DC Motor.
Control Part
Converts direct current to 3-phase alternating current and alters the compressor speed to cope with cooling demand.
Heating,Ventilation, Air Conditioning
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. If the compressor is marginally operable, run the engine, and let the air conditioning work for a few minutes, then shut the engine off.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit.
(Refer to EV Battery system - "High Voltage Shut-off Procedure")
4. Recover the refrigerant with a recovery/charging station.
•
Page 28 sur 127
If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
5. Disconnect the compressor connector (A) and high voltage connector (B) after loosening bolt.
• Disconnect high voltage connector by pressing the locker pin (A) and pressing the lever (B).
6. Remove the fixing clip of compressor high voltage cable (A).
7. Remove the engine room under cover.
(Refer to Traction Motor System - "Under Cover")
8. Remove the engine room under side cover [LH].
(Refer to Traction Motor System - "Under Cover")
9. Remove the suction hose (A) and discharge hose (B) after loosening bolts and nuts.
[Without Heat Pump]
Page 29 sur 127
[With Heat Pump]
• When separating the refrigerant line, it must cover the plug or cap for protecting the A/C system from the humidity and dust.
10. Remove the electirc A/C compressor (A) after loosening the mounting bolts.
[Without Heat Pump]
[With Heat Pump]
Page 30 sur 127
Installation
1. Make sure that the compressor mounting bolt with the correct length is screwed in. Tighten the mounting bolts to the specified tightening
order.
Tightening torque :
10.0 ~ 15.0 N.m (2.04 ~ 3.36 kgf.m, 7.37 ~ 11.0 lb-ft)
2. Install in the reverse order of removal and note the followings:
A. If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure its volume. Subtract the
volume of drained oil from 125±10cc. The result is the amount of oil you should drain from the new compressor (through the suction
fitting).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the
right O-rings for R-134a to avoid leakage.
C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
Heating,Ventilation, Air Conditioning
Troubleshooting
Fault code
Fail description
Remedy
Page 31 sur 127
60
Compressor CAN signal fault
61
Compressor operation state error receive
62
Low voltage
63
64
High voltage
Overheat protection
65
Overloaded
66
Over current protection
68
Missed restart
71
Failure of Over torque stall
67
Abnormal (not receiving)
69
Failure of thermistor open
70
Failure of thermistor short
72
Failure of short circuit current
73
Failure of driver voltage
74
Failure of current measuring
75
Failure max temperature gradient
76
Failure Internal Error
Heating,Ventilation, Air Conditioning
Component Location
[Without Heat Pump]
1. Check HV, LV connector connection.
2. Check LV connector pin condition.
3. Check vehicle inverter fuse condition.
4. A/C ON then check compressor operation.
5. If not operating, replace compressor.
1. Check HV connector connection.
2. Check vehicle inverter fuse condition.
3. Check voltage level of high voltage battery.
4. A/C ON then check compressor operation.
5. If not operating, replace compressor.
1. Identify vehicle model on compressor
2. Check voltage level of high voltage battery.
3. A/C ON then check compressor operation.
4. If not operating, replace compressor.
1. Check heating object in engine room.
2. Check A/C system for defects.
3. After 20 minutes, IG ON and A/C ON then check compressor
operation.
4. If not operating, replace compressor.
1. Check cooling fan operation.
2. Check AAF(Active Air Flap) for short circuit
3. After 20 minutes, IG ON and A/C ON then check compressor
operation.
4. If not operating, replace compressor.
1. Check 12V battery fuse.
2. Check LV connector connection.
3. Check FATC CAN connection.
4. If not operating, replace compressor.
1. Check thermistor condition and inspect.
1. Replace compressor.
2. Check vehicle inverter fuse (if necessary, replace).
Page 32 sur 127
1. Condenser
Heating,Ventilation, Air Conditioning
Inspection
1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with compressed air. If bent, gently
bend them using a screwdriver or pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.
Replacement
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
Page 33 sur 127
• Since the electric compressor uses high-voltage, you should use POE oil which have high volumetric resistivity.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit. (Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
5. Remove the side air guard (A) by pulling it upward after pressing the locking hook in the direction of the arrow.
[LH]
[RH]
6. Remove the refrigerant line (A) after loosening the mounting nuts.
7. Separate the condenser (C) from the radiator after loosening the mounting bolt.
[LH]
[RH]
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8. Remove the condenser assembly (A) from the radiator assembly.
9. Install in the reverse order of removal and note the followings :
A. If you're installing a new condenser, add refrigerant oil (POE OIL).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the
right O-rings for R-134a to avoid leakage.
C. Be careful not to damage the radiator and condenser fins when installing the condenser.
D. Be sure to install the lower mount cushions of condenser securely into the holes.
E. Charge the system, and test its performance.
Heating,Ventilation, Air Conditioning
Replacement
[Without Heat Pump]
1. Remove the condenser, and then use an L wrench to remove the bottom cap (B) from the condenser.
Tightening torque :
9.8 ~ 14.9 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)
2. Remove the desiccant (A) from the condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap filter.
Page 35 sur 127
3. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
4. Insert a new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for use.
5. Install the new bottom cap to the condenser.
• Always replace the desiccant and bottom cap at the same time.
• Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use
the right O-rings for R-134a to avoid leakage.
• Be careful not to damage the radiator and condenser fins when installing the condenser.
• Be sure to install the lower mount cushions of condenser securely into the holes.
• Charge the system, and test its performance.
[With Heat Pump]
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, you should use POE oil which have high volumetric resistivity.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit. (Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
5. Remove the receiver-drier (A) after loosening the mounting bolts.
6. Install in the reverse order of removal.
7. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
8. Insert a new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for use.
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9. Install the new bottom cap to the condenser.
• Always replace the desiccant and bottom cap at the same time.
• Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the
right O-rings for R-134a to avoid leakage.
• Be careful not to damage the radiator and condenser fins when installing the condenser.
• Be sure to install the lower mount cushions of condenser securely into the holes.
• Charge the system, and test its performance.
Heating,Ventilation, Air Conditioning
Component Location
[Without Heat Pump]
1. A/C pressure transducer
[With Heat Pump]
Page 37 sur 127
1. A/C pressure transducer
Heating,Ventilation, Air Conditioning
Description
The A/C Pressure Transducer (APT) converts the pressure value of high pressure line into voltage value after measuring it. Engine ECU
converts the voltage value to control the cooling fan by operating it in high speed or low speed. Engine ECU stops the operation of the
compressor when the temperature of refrigerant line is very high or very low irregularly to optimize air conditioning system.
Page 38 sur 127
Heating,Ventilation, Air Conditioning
Inspection
1. Measure the pressure of high pressure line by measuring voltage output between terminals No. 1 and No. 2.
2. Inspect the voltage value whether it is within the specified range.
Voltage= 0.00878835 * Pressure + 0.5[PSIA]
3. If the measured voltage value is not within the specification, replace the A/C pressure transducer.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Recover the refrigerant with a recovery/charging station.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
3. Disconnect the A/C pressure transducer connector (A).
4. Remove the A/C pressure transducer (B).
[Without Heat Pump]
Page 39 sur 127
[With Heat Pump]
• Be careful not to bend the liquid & suction pipe.
5. Install in the reverse order of removal.
• When installing, replace it with a new O-ring (A).
Heating,Ventilation, Air Conditioning
Description
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay power in order to prevent
evaporator from freezing by excessive cooling
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Heating,Ventilation, Air Conditioning
Inspection
1. Turn the ignition switch OFF.
2. Disconnect the evaporator temperature sensor connector.
3. Measure the resistance between terminals "1" and "2" of the evaporator temperature sensor.
4. Connect the evaporator temperature sensor connector.
5. Run the engine and turn the A/C switch ON, then measure the voltage between the terminals of the harness connector.
Specification
Evaporator core
temperature[°C(°F)]
Resistance[KΩ]
-10 / (14)
43.35
0 / (32)
27.62
10 / (50)
18.07
20 / (68)
12.11
30 / (86)
8.3
40 / (104)
5.81
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the console side cover (A).
[RH]
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3. Disconnect the evaporator temperature sensor connector (A).
4. Remove the evaporator temperature sensor (A) by pulling it out after rotating it 90° in a counterclockwise direction.
5. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Description
The In-car air temperature sensor is integrated into the heater & A/C control unit.
The sensor contains a thermistor which measures the temperature of the inside. The signal decided by the resistance value which changes
in accordance with perceived inside temperature, is delivered to heater control unit and according to this signal the control unit regulates incar temperature to intended value.
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Heating,Ventilation, Air Conditioning
Description
The photo sensor is located at the center of the defrost nozzles.
The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light receiving portion, generates
an electromotive force in proportion to the amount of radiation received which is transferred to the automatic temperature control module so
that the solar radiation compensation will be performed.
Heating,Ventilation, Air Conditioning
Inspection
1.
2.
3.
4.
Turn the ignition switch ON.
Connect the GDS.
Emit intensive light toward the photo sensor using a lamp, and check the output voltage change.
The voltage will rise with higher intensive light and reduce with lower intensive light.
1. Auto Light Signal
2. Auto Light Signal Signal
3. Photo Signal (RH)
4. Led power (BAT)
5. Led GND (To BCM)
6. Photo Signal (LH)
7. Photo Power (SW)
8. 5V (Vcc)
Replacement
1. Disconnect the negative (-) battery terminal.
2. With the (-) driver, remove the photo sensor (A) from the center of the defrost nozzle.
3. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Page 43 sur 127
Description
The ambient temperature sensor is located at the front of the condenser and detects ambient air temperature. It is a negative type
thermistor; resistance will increase with lower temperature, and decrease with higher temperature.
The sensor output will be used for discharge temperature control, temperature regulation door control, blower motor level control, mix mode
control and in-car humidity control.
Heating,Ventilation, Air Conditioning
Inspection
1. Turn the ignition switch OFF.
2. Disconnect ambient temperature sensor.
3. Check the resistance of the ambient temperature sensor between terminals 1 and 2 whether it is changed by changing of the ambient
temperature.
1. Sensor Ground
2. Ambient Sensor Signal
Specification
Ambient temperature
[°C(°F)]
Resistance between terminals 1and 2 (kΩ)
-10(14)
158.18
0 (32)
95.10
10 (50)
58.80
20 (68)
37.32
4. If the measured resistance is not within the specification, substitute with a known-good ambient temperature sensor and check for proper
operation.
5. If the problem is corrected, replace the ambient temperature sensor.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the engine room under cover.
(Refer to Traction Motor Systerm - "Under Cover")
3. Disconnect the connector and then remove the ambient temperature sensor (A).
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4. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Description
The cluster ionizer makes disinfection and decomposition of bad smell from the air-conditioner or inflow air. And it cleans the inside air of a
vehicle.
When the air-conditioner or heater is operating, it starts from "CLEAN" mode and alternates from "CLEAN" mode to "ION" mode and vice
versa for every 15 minutes.
In the "CLEAN" mode, the cluster ionizer generates negative ions and positive ions and disinfects and decomposes bad smells from the airconditioner or inflow air.
It has an operation indicator lamp on the display area that shows its operating status.
In the “ION” mode, the cluster ionizer generates negative ions and cleans the inside air of a vehicle. It has an operation indicator lamp on the
display area that shows its operating status.
Heating,Ventilation, Air Conditioning
Inspection
1. Press the MODE switch more than 4 times within 2 seconds while pressing the OFF switch.
Display
Fail description
00
Normal
50
Cluster ion generator fault
* For diagnostic procedures, refer to DTC code.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the glove box and glove box housing.
(Refer to Body - “Glove Box Housing”)
3. Disconnect the cluster ionizer connector (A).
4. Loosen the screws and then remove the cluster ionizer (A).
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5. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Component Location
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1. Heater unit
Components
[LH]
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1. Floor shower duct assembly [LH]
2. Duct sensor
3. Interior condenser cover
4. Heater core cover
5. Temp door arm
6. Temp door lever
7. Temp actuator motor assembly
8. Floor door lever
9. Mode actuator motor assembly [LH]
10. Mode cam
11. Motor & wheel assembly
[RH]
12. Ventilation guide
13. Heater case [LH]
14. Duct sensor
15. Joint flange cap
16. Interior condenser
17. Evaporator core lower insulation
18. Floor door assembly
19. Vent door assembly [LH]
20. Cowl top cover - Heat seal
21. Cowl top cover - Heat seal
22. Cowl top cover - Heat seal
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1. Evaporator core
2. Joint flange cap
3. Heater lower door
4. Temperature control door
5. Floor door assembly [RH]
6. Vent door assembly [RH]
7. Defogging door assembly [LH]
8. Ventilation guide
9. Heater case [RH]
10. Defogging actuator motor assembly
11. Vent door arm
12. Mode cam
13. Mode actuator motor assembly [RH]
14. PWM blower motor
15. Floor door lever
16. Floor door arm
17. Floor shower duct assembly [RH]
18. Drain hose
Heating,Ventilation, Air Conditioning
Replacement
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
• Put on gloves to protect your hands.
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• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit.
(Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
5. Remove the pipe (A) after loosening the mounting bolts.
6. Remove the expansion valve (A) after loosening the mounting bolts from the evaporator core.
Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)
• Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
7. Loosen the cowl cross member mounting bolts (A).
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8. Remove both sides of front seat assembly.
(Refer to Body - "Front Seat Assembly")
9. Remove the floor console assembly.
(Refer to Body - "Floor Console Assembly")
10. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
11. Remove the glove box housing.
(Refer to Body - "Glove Box Housing")
12. Remove the crash pad center panel.
(Refer to Body - "Crash Pad Center Panel")
13. Remove both sides of the front pillar trim.
(Refer to Body - "Front Pillar Trim")
14. Remove both sides of the cowl side trim.
(Refer to Body - "Cowl Side Trim")
15. Remove the steering column shroud lower panel.
(Refer to Body - "Steering Column Shroud Panel")
16. Remove the steering wheel.
(Refer to Steering System - "Steering Wheel")
17. Remove the multifunction switch.
(Refer to Body Electrical System - "Multifunction Switch")
18. Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
19. Remove the rear airduct assembly (A).
[LH]
(1) Remove the accelerator pedal fixing cap (A).
(2) Remove the accelerator pedal (A) after loosening the mounting bolt.
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(3) Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
(4) Bend the front floor carpet backwards.
(5) Remove the rear air duct assembly (A) after loosening the mounting nut.
[RH]
(6) Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
(7) Bend the front floor carpet (A) backwards.
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(8) Remove the rear air duct assembly (A) after loosening the mounting nut.
20. Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift Lever")
21. Disconnect the airbag control module (SRSCM) connector (A).
22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
23. Disconnect the passenger compartment junction box connectors (A).
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24. Remove the passenger compartment junction box mounting clips (A).
25. Disconnect the multi box connectors (A).
[Driver's]
[Passenger's]
26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]
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[Passenger's]
27. Remove the drain hose (A).
28. Disconnect the high voltage PTC heater cable (A).
• How to press the high voltage PTC heater cable locker pin
1. Pull the locker pin (A) in the direction of the arrow.
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2. While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
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30. Disconnect the heater and blower unit connectors.
(1) Remove the high voltage heater ground (A) after loosening the mounting bolt (B) and fixing clip (c).
(2) Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
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(3) Remove the fixing clip (B) after disconnecting the blower unit connector (A).
(4) Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
(5) Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
(6) Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
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(7) Remove the fixing clip (B) after disconnecting the mode control actuator conenctors (A).
(8) Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
31. Remove the mounting clips (A).
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32. Loosen the heater and blower unit mounting bolts (A).
33. Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.
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34. Remove the air duct (A) after loosening the mounting screw.
35. Disconnect the connector (B).
And then remove the high voltage line guide (A) after loosening the mounting screws.
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36. Disconnect the high voltage PTC heater unit connector (A).
37. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
38. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
39. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
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40. Install in the reverse order of removal and note the followings:
A. If you're installing a new evaporator, add refrigerant oil. (POE OIL)
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the
right O-rings for R-134a to avoid leakage.
C. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
D. Do not spill the refrigerant oil on the vehicle ; it may damage the paint ; if the refrigerant oil contacts the paint, wash it off
immediately
E. Apply sealant to the grommets.
F. Make sure that there is no air leakage.
G. Charge the system and test its performance.
H. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
I. Refill the cooling system with engine coolanSince the electric compressor uses high-voltage, POE oil with high resistivity should be
used.tIf PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and
the A/C compressor may not work.
Heating,Ventilation, Air Conditioning
Replacement
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit. (Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the heater and blower unit assembly.
(Refer to Heater -"Heater Unit")
• After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether. (Refer to the below removal
procedure.)
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5. Remove the fixing clip (A) after loosening the mounting screws.
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6. Remove the heater lower case (B) after loosenig the heater lower case mounting bolt (A).
7. Pull out the evaporator core (A) from the heater unit.
8. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
•
Page 65 sur 127
If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
• If you're installing a new evaporator core, add refrigerant oil (PAG OIL).
• Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use
the right O-rings for R-134a to avoid leakage.
• Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
• Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off
immediately.
• Apply sealant to the grommets.
• Make sure that there is no air leakage.
• Charge the system and test its performance.
• Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
• Refill the cooling system with engine coolant.
Heating,Ventilation, Air Conditioning
Operation Condition
1.
2.
3.
4.
5.
6.
The power supplied to the PTC heater should be within DC 240V - 420V (high voltage).
The power supplied to the PTC heater should be within 9.0V - 16.0V (low voltage).
The interlcok and insulation resistance must be normal.
The engine must be running.
The high voltage PTC heater operates depending on the operating Duty output.
If the high voltage PTC heater is abnormal, check the Fail Safe.
Heating,Ventilation, Air Conditioning
Inspection
1.
2.
3.
4.
Check for output signal in the heater and A/C control unit.
Using the GDS, check whether there is a problem in the interlock.
Check whether the low voltage (12V) is supplied or not.
For inspection, refer to the Self Diagnosis and Fail Safe.
Replacement
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
Page 66 sur 127
1. Disconnect the negative (-) battery terminal.
2. Shut off the high voltage circuit.
(Refer to EV Battery System - "High Voltage Shut-off Procedure")
3. Remove the floor console assembly.
(Refer to Body -"Floor Console Assembly")
4. Remove the crash pad lower panel.
(Refer to Body -"Crash Pad Lower Panel")
5. Remove the glove box housing.
(Refer to Body -"Glove Box Housing")
6. Remove the crash pad center panel.
(Refer to Body -"Crash Pad Center Panel")
7. Remove the TPMS receiver.
(Refer to Suspension System -"Tire Pressure Monitoring System")
8. Remove the high voltage PTC heater ground (A) after loosening the mounting bolt.
9. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
10. Disconnect the high voltage PTC heater cable (A).
• How to press the high voltage PTC heater cable locker pin
1. Pull the locker pin (A) in the direction of the arrow.
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2. While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
11. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
12. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
13. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Description
The heater unit includes mode control actuator and temperature control actuator.
Located in the heater unit, the temperature control actuator regulates the temperature in the following procedures.
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Signal from control unit adjusts the position of the temperature door by operating the temperature switch. Then the temperature will be
regulated by the hot/cold air ratio decided by the position of the temperature door.
Heating,Ventilation, Air Conditioning
Inspection
1. Turn the ignition switch OFF.
2. Disconnect the temperature control actuator connector.
3. Verify that the temperature control actuator operates to the cool position when 12V is connected to terminal 3 and ground to terminal 7.
Verify that the temperature control actuator operates to the warm position when connected in reverse.
1. 2. 3. Cool position
4. Sensor (+ 5V)
5. Feedback signal
6. Sensor ground
7. Warm position
4. Connect the temperature control actuator connector.
5. Turn the ignition switch ON.
6. Check the voltage between terminals 5 and 4.
Specification
Door Position
Voltage (V)
Error Detecting
Max. cooling
0.3±0.15
Max. heating
4.7±0.15
Low voltage : 0.1V or less
High voltage : 4.9V or more
It will feedback the current position of the actuator to controls.
7. If the temperature control actuator does not operate well, substitute with a known-good temperaturecontrol actuator and check for proper
operation. Use the replaced actuator if it performs well.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the driver's side shower duct (A) after loosening the screw.
4. Disconnect the connector (A) and then remove the temperature control actuator (B) after loosening the mounting screws.
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5. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Description
Located in the heater unit, the mode control actuator adjusts the position of the mode door by operating the mode control actuator according
to the signal from the A/C control unit. Pressing the mode select switch shifts the mode control actuator in the order of Vent → Bi-Level →
Floor → Mix.
Heating,Ventilation, Air Conditioning
Inspection
1. Turn the ignition switch OFF.
2. Disconnect the mode control actuator connector.
3. Verify that the mode control actuator operates to the defrost mode when 12V is connected to terminal 3 and ground to terminal 7.
Verify that the mode control actuator operates to the vent mode when connected in reverse.
1. 2. 3. Defrost mode
4. Sensor ground
5. Feedback signal
6. Sensor (+ 5V)
7. Vent mode
4. Connect the mode control actuator connector.
5. Turn the ignition switch ON.
6. Check the voltage between terminals 5 and 4.
Specification
Door position
Voltage (V)
Error detecting
Vent
0.3±0.15
Defrost
4.7±0.15
Low voltage : 0.1V or less
High voltage : 4.9V or more
It will feedback the current position of the actuator to controls.
7.
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If the mode control actuator does not operate well, substitute with a known-good mode control actuator and check for proper operation.
Use the replaced actuator if it performs well.
Replacement
[Driver's Mode Actuator]
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the driver shower duct (A) after loosening the mounting screw.
4. Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
5. Disconnect the mode control actuator connector (A).
And then remove the mode control actuator (B) after loosening the mounting screws.
6. Install in the reverse order of removal.
[Passenger's Mode Actuator]
1. Disconnect the negative (-) battery terminal.
2. Remove the main crash pad assembly.
(Refer to Body - "Main Crash Pad Assembly")
3. Disconnect the mode control actuator connector (A).
And then remove the mode control actuator (B) after loosening the mounting screws.
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4. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Inspection
1. Turn the ignition switch OFF.
2. Disconnect the negative (-) battery terminal.
3. Verify that the auto defogging actuator operates to the open position when 12V is connected to terminal 3 and ground to terminal 4.
Verify that the auto defogging actuator operates to the close position when connected in reverse.
4. Connect the auto defogging actuator connector.
5. Turn the ignition switch ON.
6. Check the voltage between terminals 5 and 6.
1. -
5. Sensor ground
2. -
6. Feedback signal
3. DEF (OFF)
7. Sensor (+ 5V)
4. DEF (ON)
Specification
Door position
Voltage (V)
Error detecting
Defog OFF (CLOSE)
0.30±0.15
Defog ON (OPEN)
3.0±0.15
Low voltage : 0.1V or less
High voltage : 4.9V or more
It will feedback the current position of the actuator to controls.
7. If the auto defogging actuator does not operate well, substitute with a known-good auto defogging actuator and check for proper
operation. Use the replaced actuator if it performs well.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the driver shower duct (A) after loosening the mounting screw.
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4. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Heat Pump Configuration and Operation
Heat pump is configured to circulate refrigerant flow for cooling/heating function.
This process minimizes battery consumption by the heater resulting in enhanced driving distance of EV.
[Heating]
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Outer Condenser - Evaporates liquid refrigerant and forms low temp-low pressure gas substance.
3-Way Solenoid Valve #2 - Redirects the refrigerant direction towards the chiller when heat pump is active.
Chiller - Uses waste heat from the motor and performs secondary heat exchange on low temp-low pressure gas.
Accumulator - Separates gas/liquid so that only the refrigerant in gas state can flow into the compressor.
Electric Compressor - Compressor is operated by electric motor. Converts low temp-low pressure gas refrigerant into high temp-high
pressure gas and sends it to inner condenser.
Inner Condenser - Condenses high temp-high pressure gas refrigerant and transforms it into high temp-high pressure liquid refrigerant.
2-Way Solenoid Valve #1 - Instantly expands refrigerant to create low temp-low pressure refrigerant.
2-Way Solenoid Valve #2 - Sends the refrigerant to the evaporator if DEFROST Mode is used when heating.
3-Way Solenoid Valve #1 - Bypasses the refrigerant to chiller if refrigerant accumulation in the outer condenser is detected.
[Cooling]
1.
2.
3.
4.
Outer Condenser - Condenses high temp-high pressure gas refrigerant and transforms it into high temp-high pressure liquid refrigerant.
3-Way Valve #2 - Directs refrigerant flow to expansion valve when A/C is operating.
Expansion Valve - Instantly expands refrigerant to create low temp-low pressure gas.
Evaporator - Operates blower fan to cool the air passing through the evaporator pin while the refrigerant in foggy state is transformed into
gas (surrounding area gets cold).
5. Accumulator - Separates gas/liquid so that only gas state refrigerant can flow into the compressor.
6. Electric Compressor - Compressor is operated by electric motor. Converts low temp-low pressure gas refrigerant into high temp-high
pressure gas and sends it to inner condenser.
7. Inner Condenser - Condenses high temp-high pressure gas refrigerant and transforms it into high temp-high pressure liquid refrigerant.
8. 2-Way Solenoid Valve #1 - Does not expand but circulates refrigerant when A/C is operating.
9. 2-Way Solenoid Valve #2 - Prevents refrigerant from flowing into evaporator.
10. 3-Way Solenoid Valve #1 - Circulates refrigerant to outer condenser.
Heating,Ventilation, Air Conditioning
Components Location
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1. 3-Way Solenoid Valve Assembly
2. 2-Way Solenoid Valve Assembly
Heating,Ventilation, Air Conditioning
Description
Changes the valve outlet direction with an electric signal to switch the refrigerant flow direction. This switching of refrigerant flow direction
allows activation of A/C Mode and Heat Pump Mode.
Heating,Ventilation, Air Conditioning
Inspection
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1. Vcc
2. Ground
Check the voltage between terminals 6 and 7.
1. Using the tester, check the resistance between terminals 1 and 2.
Temperature
Resistance [KΩ]
°C
°F
-30
-22
8.7~9.5
-25
-13
8.92~9.74
-20
-4
9.14~9.98
-15
5
9.37~10.23
-10
14
9.59~10.47
-5
23
9.81~10.71
0
32
10.03~10.95
5
41
10.25~11.19
10
50
10.47~11.43
15
59
10.69~11.67
20
68
10.90~11.90
25
77
11.12~12.14
30
86
11.34~12.38
35
95
11.55~12.61
40
104
11.77~12.85
Replacement
[3-WAY Solenoid Valve]
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.Since the electric compressor uses
high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Disconnect the 3-WAY solenoid valve connector (A).
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4. Remove the refrigerant line after loosening the mounting nuts (A).
5. Remove the 3-WAY solenoid valve assembly (A) after loosening the mounting bolt and nut.
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6. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
[2-WAY Solenoid Valve]
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Disconnect the 2-WAY solenoid valve connector (A).
4. Remove the refrigerant line after loosening the mounting nuts (A).
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5. Remove the 3-WAY solenoid valve assembly (A) after loosening the mounting bolt and nut.
6. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
Heating,Ventilation, Air Conditioning
Components Location
Page 79 sur 127
1. Accumulator
Heating,Ventilation, Air Conditioning
Description
Separates refrigerant in gas/liquid state so that only the refrigerant in gas state can flow into the compressor.
Heating,Ventilation, Air Conditioning
Page 80 sur 127
Replacement
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Remove the refrigerant line after loosening the mounting nuts (A).
4. Remove the accumulator (A) after loosening the mounting bolt.
5. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
Heating,Ventilation, Air Conditioning
Components Location
Page 81 sur 127
1. Refrigerant Temperature Sensor #1
2. Refrigerant Temperature Sensor #2
Heating,Ventilation, Air Conditioning
Description
Monitors refrigerant temperature in A/C duct and sends resistance data to A/C controller. (same as the thermistor)
Temperature and resistance is inversely proportioned.
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Heating,Ventilation, Air Conditioning
Inspection
1. Vcc
2. Ground
Check the voltage between terminals 6 and 7.
1. Using the tester, check the resistance between terminals 1 and 2.
Temperature
Resistance
°C
°F
Specification [KΩ]
-40
-40
225.1
Tolerance [%]
± 3.06
-30
-22
129.3
± 2.49
-20
-4
76.96
± 1.95
-10
14
47.34
± 1.46
0
32
30
± 1.00
10
50
19.53
± 1.43
20
68
13.03
± 1.82
30
86
8.896
± 2.19
40
104
6.201
± 2.54
50
122
4.406
± 2.86
60
140
3.186
± 3.16
70
158
2.343
± 3.44
80
176
1.749
± 3.71
90
194
1.325
± 3.96
100
212
1.017
± 4.20
110
230
0.789
± 4.42
120
248
0.62
± 4.63
Replacement
[Refrigerant Temperature Sensor #1]
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Seperate the charge door handle (A).
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3. Loosen the clips and bolts on the front bumper upper cover.
4. Lift the front bumper uppser cover (A) slightly.
5. Remove the front bumper upper cover (A) after loosening the mounting screw (B) on the side.
6. Remove the refrigerant temperature sensor #1 (B) after disconnecting the refrigerant temperature sensor #1 connector (A).
7. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
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[Refrigerant Temperature Sensor #2]
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Remove the refrigerant temperature sensor #2 (B) after disconnecting the refrigerant temperature sensor #2 connector (A).
3. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
Heating,Ventilation, Air Conditioning
Components Location
Page 85 sur 127
1. Inner Condenser
Heating,Ventilation, Air Conditioning
Description
Uses high temp-high pressure refrigerant to warm the air flowing into the interior (same role as the heater core in a conventional system).
Heating,Ventilation, Air Conditioning
Replacement
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
• Put on gloves to protect your hands.
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• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit. (Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the cowl top cover.
(Refer to Body -"Cowl Top Cover")
5. Remove the pipe (A) after loosening the mounting bolts.
6. Remove the expansion valve (A) after loosening the mounting bolts from the evaporator core.
Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)
• Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
7. Loosen the cowl cross member mounting bolts (A).
8. Remove both sides of front seat assembly.
(Refer to Body - "Front Seat Assembly")
9. Remove the floor console assembly.
(Refer to Body - "Floor Console Assembly")
10. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
11. Remove the glove box housing.
(Refer to Body - "Glove Box Housing")
12. Remove the crash pad center panel.
(Refer to Body - "Crash Pad Center Panel")
13. Remove both sides of the front pillar trim.
(Refer to Body - "Front Pillar Trim")
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14. Remove both sides of the cowl side trim.
(Refer to Body - "Cowl Side Trim")
15. Remove the steering column shroud lower panel.
(Refer to Body - "Steering Column Shroud Panel")
16. Remove the steering wheel.
(Refer to Steering System - "Steering Wheel")
17. Remove the multifunction switch.
(Refer to Body Electrical System - "Multifunction Switch")
18. Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
19. Remove the rear airduct assembly (A).
[LH]
(1) Remove the accelerator pedal fixing cap (A).
(2) Remove the accelerator pedal (A) after loosening the mounting bolt.
(3) Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
(4) Bend the front floor carpet backwards.
(5) Remove the rear air duct assembly (A) after loosening the mounting nut.
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[RH]
(1) Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
(2) Bend the front floor carpet (A) backwards.
(3) Remove the rear air duct assembly (A) after loosening the mounting nut.
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20. Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift Lever")
21. Disconnect the airbag control module (SRSCM) connector (A).
22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
23. Disconnect the passenger compartment junction box connectors (A).
24. Remove the passenger compartment junction box mounting clips (A).
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25. Disconnect the multi box connectors (A).
[Driver's]
[Passenger's]
26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]
[Passenger's]
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27. Remove the drain hose (A).
28. Disconnect the high voltage PTC heater cable (A).
• How to press the high voltage PTC heater cable locker pin
(1) Pull the locker pin (a) in the direction of the arrow.
(2) While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
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29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
30. Remove the interior condensor cover (A) after loosening the mounting screws.
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31. Remove the interior condenser (A) in the direction of the arrow.Since the electric compressor uses high-voltage, POE oil with high
resistivity should be used.
32. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
• If you're installing a new condenser, add refrigerant oil (POE OIL).
• Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use
the right O-rings for R-134a to avoid leakage.
• Be careful not to damage the radiator and condenser fins when installing the condenser.
• Be sure to install the lower mount cushions of condenser securely into the holes.
• Charge the system, and test its performance.
Heating,Ventilation, Air Conditioning
Components Location
Page 94 sur 127
1. Outer Condenser
Heating,Ventilation, Air Conditioning
Description
Condenses high temp-high pressure refrigerant when in A/C Mode (same role as the condenser in a conventional system).
Evaporates low temp-low pressure refrigerant when in Heating Mode (same role as the evaporator in a conventional system).
It is designed as down-flow type to facilitate condensed liquid discharge.
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Heating,Ventilation, Air Conditioning
Replacement
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
• Put on gloves to protect your hands.
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit. (Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the front bumper cover.
(Refer to Body -"Front Bumper Cover")
5. Remove the ambient temperature sensor.
(Refer to Heating,Ventilation, Air Conditioning -"Ambient Temperature Sensor")
6. Remove the refrigerant temperature sensor #1.
(Refer to Heating,Ventilation, Air Conditioning -"Refrigerant Temperature Sensor #1")
7. Separate the refrigerant line (A) after loosening the mounting nuts.
• Cap the open fittings immediately to keep moisture or dirt out of the system.
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8. Pull out the side air guides (A) after pushing locker hook in the direction of the arrow.
9. Separate the exterior condensor (B) from the radiator after loosening bolts (A).
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10. Remove the exterior condenser (A) in the direction of the arrow.Since the electric compressor uses high-voltage, POE oil with high
resistivity should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
• If you're installing a new condenser, add refrigerant oil (POE OIL).
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• Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use
the right O-rings for R-134a to avoid leakage.
• Be careful not to damage the radiator and condenser fins when installing the condenser.
• Be sure to install the lower mount cushions of condenser securely into the holes.
• Charge the system, and test its performance.
Heating,Ventilation, Air Conditioning
Components Location
1. Chiller
Heating,Ventilation, Air Conditioning
Description
Recycles waste electric heat by using the waste heat from electrical motor to exchange heat in low temperature refrigerant.
Page 99 sur 127
Heating,Ventilation, Air Conditioning
Replacement
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Drain the coolant.
(Refer to Traction Motor System - "Coolant")
3. Disconnect the negative (-) battery terminal.
4. Remove the reservoir tank.
(Refer to Traction Motor System - "Reservoir")
5. Separate the refrigerant line (A) after loosening the mounting bolt.
• Cap the open fittings immediately to keep moisture or dirt out of the system.
6. Separate the refrigerant line (A) after loosening nut and then remove the chiller coolant hose (B).
• Cap the open fittings immediately to keep moisture or dirt out of the system.
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7. Remove the chiller (A) after loosening the mounting bolts.
8. Install in the reverse order of removal.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
Heating,Ventilation, Air Conditioning
3-Way Coolant Valve
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1. 3-Way Coolant Valve
Heating,Ventilation, Air Conditioning
Description
Switches the valve outlet direction through electric signal to change refrigerant flow direction.
Directs refrigerant flow towards chiller when heating pump is activated.
Directs refrigerant flow towards radiator during normal condition.
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1. Towards radiator
2. Towards chiller
3. Inlet
Heating,Ventilation, Air Conditioning
Replacement
1. Drain the coolant.
(Refer to Traction Motor System - "Coolant")
2. Disconnect the negative (-) battery terminal.
3. Disconnect the 3-WAY solenoid coolant valve connector (A).
4. Remove the 3-WAY coolant valve connector fixing clip (B).
5. Remove the coolant hose (A) above 3-WAY coolant valve.
6. Remove the coolant hose (A).
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7. Remove the 3-WAY coolant valve (B) after loosening the mounting bolts.
8. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Component Location
1. Blower unit
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Components
1. High voltage PTC heater core
2. Ionizer
3. Evaporator temperature sensor
4. Air inlet filter cover assembly
5. Heater core pipe mounting bracket
6. Heater - evaporator seal
7. Intake duct case [LH]
8. Intake arm
9. Intake actuator motor assembly
10. Intake cam
11. Intake arm
12. Blower - crash pad seal
13. Air filter
14. Inlet door assembly
15. Case clip
16. Air inlet door assembly
17. Intake duct case [LH]
18. Evaporator - heater seal
Heating,Ventilation, Air Conditioning
Replacement
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
• Put on gloves to protect your hands.
Page 105 sur 127
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
1. Recover the refrigerant with a recovery/ recycling/ charging station.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
• Since the electric compressor uses high-voltage, POE oil with high resistivity should be used..
• If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the
A/C compressor may not work.
2. Disconnect the negative (-) battery terminal.
3. Shut off the high voltage circuit. (Refer to EV Battery System - "High Voltage Shut-off Procedure")
4. Remove the cowl top cover.
(Refer to Body - "Cowl Top Cover")
5. Remove the pipe (A) after loosening the mounting bolts.
6. Remove the expansion valve (A) after loosening the mounting bolts from the evaporator core.
Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)
• Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
• Replace the O-rings with new ones.
7. Loosen the cowl cross member mounting bolts (A).
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8. Remove both sides of front seat assembly.
(Refer to Body - "Front Seat Assembly")
9. Remove the floor console assembly.
(Refer to Body - "Floor Console Assembly")
10. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
11. Remove the glove box housing.
(Refer to Body - "Glove Box Housing")
12. Remove the crash pad center panel.
(Refer to Body - "Crash Pad Center Panel")
13. Remove both sides of the front pillar trim.
(Refer to Body - "Front Pillar Trim")
14. Remove both sides of the cowl side trim.
(Refer to Body - "Cowl Side Trim")
15. Remove the steering column shroud lower panel.
(Refer to Body - "Steering Column Shroud Panel")
16. Remove the steering wheel.
(Refer to Steering System - "Steering Wheel")
17. Remove the multifunction switch.
(Refer to Body Electrical System - "Multifunction Switch")
18. Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
19. Remove the rear airduct assembly (A).
[LH]
(1) Remove the accelerator pedal fixing cap (A).
(2) Remove the accelerator pedal (A) after loosening the mounting bolt.
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(3) Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
(4) Bend the front floor carpet backwards.
(5) Remove the rear air duct assembly (A) after loosening the mounting nut.
[RH]
(1) Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
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(2) Bend the front floor carpet (A) backwards.
(3) Remove the rear air duct assembly (A) after loosening the mounting nut.
20. Remove the shift lever assembly.
(Refer to Automatic Transaxle System - "Shift Lever")
21. Disconnect the airbag control module (SRSCM) connector (A).
22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A)..
23. Disconnect the passenger compartment junction box connectors (A).
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24. Remove the passenger compartment junction box mounting clips (A).
25. Disconnect the multi box connectors (A).
[Driver's]
[Passenger's]
26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]
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[Passenger's]
27. Remove the drain hose (A).
28. Disconnect the high voltage PTC heater cable (A).
• How to press the high voltage PTC heater cable locker pin
(1) Pull the lock pin (A) in the direction of the arrow.
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(2) While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
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30. Disconnect the heater and blower unit connectors.
(1) Remove the high voltage heater ground (A) after loosening the mounting bolt (B) and fixing clip (c).
(2) Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
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(3) Remove the fixing clip (B) after disconnecting the blower unit connector (A).
(4) Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
(5) Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
(6) Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
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(7) Remove the fixing clip (B) after disconnecting the mode control actuator connectors (A).
(8) Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
31. Remove the mounting clips (A).
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32. Loosen the heater and blower unit mounting bolts (A).
33. Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.
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34. Remove the air duct (A) after loosening the mounting screw.
35. Disconnect the connector (B).
And then remove the high voltage line guide (A) after loosening the mounting screws.
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36. Disconnect the high voltage PTC heater unit connector (A).
37. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
38. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
39. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
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40. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Inspection
1. Connect the battery voltage and check for the blower motor rotation.
2. If the blower motor voltage does not operate well, substitute with a verified blower motor and check for proper operation.
3. If the problem is corrected, replace the blower motor.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the driver shower duect (A) after loosening the mounting screw.
4. Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "Steering Column and Shaft")
5. Remove the fixing clip (B) after disconnecting the mode control actuator connector (A).
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6. Disconnect the temperature control connector (A).
And then remove the temperature control actuator (B) after loosening the mounting screws.
7. Remove the brake pedal.
(Refer to Brake System - "Brake Pedal")
8. Disconnect the blower motor connector (A).
And then remove the blower motor (B) after loosening the mounting screws.
9. Install the reverse order of removal.
Heating,Ventilation, Air Conditioning
Inspection
1. Turn the ignition switch OFF.
2. Manually operate the control switch and measure the voltage of blower motor.
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3. Select the control switch to raise voltage until high speed.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the glove box housing.
(Refer to Body - "Glove Box Housing")
3. Disconnect the connector (A) and then remove the blower resistor (B) after loosening the mounting screws.
4. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Description
The climate control air filter is located in the blower unit. It eliminates foreign materials and odor. The particle filter performs a role as an odor
filter as well as a conventional dust filter to ensure comfortable interior environment.
Heating,Ventilation, Air Conditioning
Replacement
1. Open the glove box (A).
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2. Remove the air filter panel (A).
3. Remove the filter cover (A) by pressing the filter cover knob.
4. Replace the air filter (A) with a new one according to the direction of air filter.
• To remove the filter easily, press the righthand side inward and then pull out the filter.
• In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as possible.
5. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Description
Page 122 sur 127
The intake actuator is located in the blower unit. It regulates the intake door by signal from control unit. Pressing the intake selection switch
will shift between recirculation and fresh air modes.
Heating,Ventilation, Air Conditioning
Inspection
1. Turn the ignition switch OFF.
2. Disconnect the intake actuator connector.
3. Verify that the actuator operates to the recirculation position when 12V is connected to terminal 3 and ground to terminal 7.
Verify that the intake actuator operates to the recirculated air position when connected in reverse.
1. -
5. Feedback signal
2. -
6. Sensor ground
3. Fresh air
7. Recirculated air
4. Sensor (+ 5V)
4. Connect the intake actuator connector.
5. Turn the ignition switch ON.
6. Check the voltage between terminals 5 and 6.
Specification
Door position
Voltage (V)
Error detecting
Fresh air
0.3±0.15
Recirculated air
4.7±0.15
Low voltage : 0.1V or less
High voltage : 4.9V or more
It will feedback the current position of the actuator to controls.
7. If the intake actuator does not operate well, substitute with a verified intake actuator and check for proper operation. Use the replaced
actuator if it performs well.
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the glove box housing.
(Refer to Body - "Glove Box Housing")
3. Disconnect the connector (A) and then remove the intake actuator (B) after loosening the mounting screws.
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4. Install in the reverse order of removal.
Heating,Ventilation, Air Conditioning
Components
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Connector Pin Function
Pin
No.
Connector A
Connector B
Connector C
Electric compressor interlock (+)
1
ILL (+)
Ground
2
Sensor REF (+5V)
Sensor ground
Electric compressor interlock (-)
3
C_CAN High
Blower PWM IN
High voltage PTC heater interlock (+)
4
C_CAN LOW
Ionizer diagnosis
High voltage PTC heater interlock (-)
5
Driver mode actuator (VENT)
-
PAB IGN3
6
Driver mode actuator (DEF)
CLEAN signal
PAB ON signal
7
Driver mode actuator F/B
Passenger mode actuator (VENT)
PAB OFF signal
8
Intake actuator (FRE)
Passenger mode actuator (DEF)
SBR
9
Intake actuator (REC)
Passenger mode actuator F/B
Rr LEFT SBR
10
Intake actuator F/B
Defogging actuator (OPEN)
Rr CENTER SBR
11
K-LINE
Defogging actuator (CLOSE)
Rr RIGHT SBR
12
HTD
Defogging actuator F/B
-
13
Rear defog switch
Vent left duct sensor (+)
-
14
Temp. control actuator (COOL)
Floor left duct sensor (+)
-
15
Temp. control actuator (WARM)
IGN3
-
16
Temp. Control actuator F/B
IGN2
-
17
Left seat heater indicator - LOW
-
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18
Left seat heater indicator - MID
2 WAY valve #1 (+)
19
Left seat heater indicator - HIGH
3 WAY valve #1 (+)
20
ILL - (RHEO)
3 WAY valve #2 (+)
21
DETENT OUT (+)
2 WAY valve #2 (+)
22
Left seat heater switch
CLIMATE_CAN HIGH
23
Left ventilation indicator - LOW
CLIMATE_CAN LOW
24
Left ventilation indicator - MID
HUMIDITY (PWM)
25
Left ventilation indicator - HIGH
Air pressure tranducer signal
26
Right seat heater switch
Refrigerant temperature sensor signal #1
27
Ambient sensor (+)
Refrigerant temperature sensor signal #2
28
Evaporator sensor (+)
Coolant valve OUTPUT
29
Right ventilation indicator - LOW
IGN3
30
Right ventilation indicator - MID
Blower IS
31
Right ventilation indicator - HIGH
Battery
32
Photo sensor (-)
Battery
33
Right ventilation switch
34
Left ventilation switch
35
Blower INH
36
MM_CAN HIGH
37
MM_CAN LOW
38
Right seat heater indicator - LOW
39
Right seat heater indicator - MID
40
Right seat heater indicator - HIGH
Heating,Ventilation, Air Conditioning
Self Diagnosis
1. Self-diagnosis process
2. How to read self-diagnostic code
After the display panel flickers three times every 0.5 second, the corresponding fault code flickers on the setup temperature display panel
every 0.5 second and will show two figures. Codes are displayed in numerical format
3. Fault code display
(1) Continuous operation : DTC code for one.
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(2) Continuous operation : DTC code for two or more.
(3) STEP operation
A. Same as continuous operation when normal or one fault code.
B. DTC code for two or more.
Replacement
• When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent
damage.
• Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
• Take care not to bend or scratch the trim and panels.
• Put on gloves to protect your hands.
1. Disconnect the negative (-) battery terminal.
2. Using a screwdriver or remover, remove the center fascia panel (A).
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3. Disconnect the A/C & heater controller connectors (A).
4. Remove the heater & A/C controller unit (A) from the center fascia panel (B) after loosening the mounting screws.
5. Install in the reverse order of removal.
• Make sure that the connectors are connected in properly.
• Replace any damaged clips.
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EV Battery System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to “High
Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety accidents
(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high voltage
battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
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Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high voltage
battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
EV Battery System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current Sensor,
Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit (EPCU), High
Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
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3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
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(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
EV Battery System
High voltage battery system inspection guide
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
1. Carry out a visual inspection to determine whether the vehicle requires general repair or accident repair.
2. For the general repair, repair according to the repair process of the corresponding DTC code.
3. For the car accident repair, determine the accident type before repairing.
1) Electrical Accidents
- Over-charge/discharge: Displays a battery over voltage (P1B71) code /low voltage (P1B70) code (Refer to the DTC diagnosis guide).
- Short: Displays a high voltage short (P1B77, P1B25) codes (Refer to the DTC diagnosis guide).
2) Fire
Classification
Inspection process
1.
Inspection results
Measures
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Fire outside the high
voltage battery mount
2.
e.g. fire in engine
3.
4.
5.
6.
Perform visual inspections (deformation,
corrosion, wire coating, odor, connector).
Check for main fuse open circuit after
shutting off the high voltage.
Check the high voltage main relay for
signs of welding.
Measure the high voltage battery/chassis
insulation resistance.
Check other parts for failure.
Check the DTC code in the BMS ECU.
Fire in the high voltage 1. Perform visual inspections (deformation,
corrosion, wire coating, odor, connector).
battery mount
2. Check for visible damage of the high
voltage battery.
e.g. fire in trunk
3. Check the high voltage main relay for
signs of welding after shutting off the high
voltage if no visible damage is found in the
high voltage battery.
4. Measure the high voltage battery/chassis
insulation resistance.
5. Check other parts for failure.
6. Check the DTC code in the BMS ECU.
High voltage battery insulation
damaged
Remove the high voltage battery
and repair the insulation
process/coating.
High voltage
battery not
damaged
DTC code
If a DTC code occurs, comply
with DTC diagnosis guide and
repair process.
No DTC code and
battery appears
normal
Do not replace the high voltage
battery (if the battery is damaged
and must be disposed of,
perform the high voltage battery
disposal process).
Remove the service disconnect
plug and perform the salt water
battery disposal process.
High voltage battery appears
damaged (heat, soot, etc.)
High voltage battery insulation
damaged
Remove the high voltage battery
and repair the coating/insulation.
High voltage
battery not
damaged
DTC code
If a DTC code occurs, perform
the repair process outlined in the
DTC diagnosis guide.
No DTC code and
battery appears
normal
Do not replace the high voltage
battery (if the battery is damaged
and must be disposed of,
perform the high voltage battery
disposal process).
3) Collision
Classification
Inspection process
Inspection results
Measures
1. Perform visual inspections (deformation,
corrosion, wire coating, odor, connector).
2. Check for main fuse open circuit after
shutting off the high voltage.
3. Check the high voltage main relay for
e.g. front/side collisions
signs of melting.
4. Measure the high voltage battery/chassis
insulation resistance.
5. Check other components.
6. Check the DTC code in the BMS ECU.
High voltage battery insulation
damaged
Remove the high voltage battery
and repair the coating/insulation.
High voltage
battery not
damaged
DTC code
If a DTC code occurs, perform
the repair process outlined in the
DTC diagnosis guide.
No DTC code and
battery appears
normal
Do not replace the high voltage
battery (if the battery is damaged
and must be disposed of,
perform the high voltage battery
disposal process).
Collisions involving the 1. Perform visual inspections (deformation,
high voltage battery
corrosion, wire coating, odor, connector).
mount
2. Check for main fuse open circuit after
shutting off the high voltage.
※Example)
3. Check the high voltage main relay for
Rear-end collision
signs of melting.
4. Measure the high voltage battery/chassis
insulation resistance.
5. Check other components.
6. Check the DTC code in the BMS ECU.
High voltage battery insulation
damaged
Collision damage to
areas other than the
high voltage battery
mount
High voltage
battery not
damaged
DTC code
No DTC code and
battery appears
normal
⇑ Follow the measures outlined
above.
※ If the high voltage battery
mount is inaccessible due to
trunk or door damage, bend or
cut the exterior panels without
damaging the high voltage
system and carry out the
inspection and repair process.
4) Submersion
Classification
Inspection process
High voltage battery not 1. Perform a visual inspection (deformation,
submerged
corrosion, wire coating, odor, connector).
2. Check for main fuse open circuit after
shutting off the high voltage.
3. Check the high voltage main relay for
signs of melting.
4. Measure the high voltage battery/chassis
insulation resistance.
5. Check other components.
6. Check the DTC code in the BMS ECU.
1. Check for main fuse open circuit after
High voltage battery
shutting off the high voltage.
submerged
2. Check the high voltage main relay for
[Regardless of water
conditions]
signs of melting.
Inspection results
Measures
High voltage battery insulation
damaged
Remove the high voltage battery
and repair the coating/insulation.
High voltage
battery not
damaged
DTC code
If a DTC code occurs, perform
the repair process outlined in the
DTC diagnosis guide.
No DTC code and
battery appears
normal
Do not replace the high voltage
battery (if the battery is damaged
and must be disposed of,
perform the high voltage battery
disposal process).
Carry out these measures
regardless of the inspection results
Remove the high voltage battery
and repair the coating/insulation.
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3. Measure the high voltage battery/chassis
insulation resistance.
4. Check the DTC code in the BMS ECU.
Main Fuse Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
Method 1
1. Remove the safety plug.
(Refer to High Voltage Battery Control System - "Safety Plug")
2. Measure the resistance of safety plug cable which is connected to main fuse.
Specification :Less than 1Ω (20°C)
Method 2
1. Turn the ignition switch OFF and disconnect the auxiliary battery negative (-) terminal.
2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
4. Remove the upper fuse box (A).
5. Perform the electrical test of main fuse.
Specification :Less than 1Ω (20°C)
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Checking for Welding in the High Voltage Main Relay
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
In order to safely remove the battery pack assembly, you must first inspect the high voltage main relay for signs of damage on welding.
You can use Global Diagnostic System (GDS) service data to detect weld damage in the high voltage main relay.
1. Connect the GDS to DLC.
2. Turn the ignition switch ON.
3. Check the BMS weld damage state in the GDS service data.
Specification :NO
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• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Shut off the high voltage.
(Refer to "High voltage Shut-off Procedures”)
2. Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Battery Pack Assembly")
3. Remove the upper case.
(Refer to High Voltage Battery System - "Case")
4. Remove the protect cover (A) of power relay assembly (PRA).
5. Check for damage on welding in the high voltage main relay.
Specification :∞Ω(20°C)
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Insulation Resistance Inspection (With vehicle)
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
The insulation status between the vehicle and the battery pack assembly can be checked on GDS or by measuring the resistance.
1. Connect the GDS to DLC.
2. Turn the ignition switch ON.
3. Inspect the insulation resistance in the GDS service data.
Specified value :300KΩ ~ 1000KΩ
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• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shout-off Procedure")
2. Connect the negative (-) terminal of mega ohm meter (A) to ground of the vehicle.
For precise measuring, connect the negative (-) terminal to the parts not painted.
3. After connecting the positive (+) terminal to positive (+) terminal of the battery, measure the resistance as follows.
(1) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) Check the resistance.
Specified value : More than 2MΩ (20°C)
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4. After connecting the positive (+) terminal to negative (-) terminal of the battery, measure the resistance as follows.
(1) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) Check the resistance.
Specified value : More than 2MΩ (20°C)
Insulation Resistance Inspection (With battery)
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Battery Pack Assembly")
2. Remove the upper case of high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Case")
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3. Remove the protect cover (A) of power relay assembly (PRA).
4. Connect the negative (-) terminal of mega ohm meter to lower case.
For precise measuring, connect the negative (-) terminal to the parts not painted.
5. Connect the positive (+) terminal to high voltage battery (+, -) terminals to measure the resistance.
(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA high voltage.
(2) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) Check the reistance value.
Specified value : More than 2MΩ (20°C)
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(1) Connect the positive (+) terminal of mega ohm meter (B) to negative (-) terminal of PRA high voltage.
(2) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) Check the reistance value.
Specified value : More than 2MΩ (20°C)
(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA inverter power.
(2) Supply the 500V voltage through mega ohm meter and then wait about 1 minutes to measure the stable resistance value
(3) Check the reistance value.
Specified value : More than 2MΩ (20°C)
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(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (-) terminal of PRA inverter power.
(2) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) Check the reistance value.
Specified value : More than 2MΩ (20°C)
Handling Guide for Storing, Transporting, and Disposing of High Voltage Battery Systems
1. High voltage battery system handling process
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2. Defective high voltage battery system handling / Inspection
Classification
Item
Storage
Undamaged Battery
Transport Minimize impacts and ensure the battery does not come in contact with other parts.
Disposal
Damaged
battery
Common
Measures
Remove the service disconnect and store the battery under the same conditions as a new battery.
Inspection
method
Transport the battery to the designated disposer
1. Voltage check(using a digital multimeter)
(1) Measure the voltage between the service disconnect plug upper (+) terminal and [High
voltage battery – PRA] connecting cable (-) terminal.
→ Specification:
(2) Measure the voltage between the service disconnect plug lower (-) terminal and [High voltage
battery – PRA] connecting cable (+) terminal.
→ Specification:
(3) Measure the voltage between the high voltage battery (+) cable terminal and high voltage
battery (-) cable terminal
→Specification:240 ~ 413 V
▶ Measures: If abnormal, submerge the battery in salt water immediately to prevent fire.
2. Temperature check(using a non-contact thermometer)
(1) Check the temperature of battery case.
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(2) Check for temperature changes by measuring the temperature again after 30 minutes.
▶ Criteria: The change should be 3 °C or less and the temperature should be below 35 °C.
▶ Measures
A. If the temperature is higher than 35°C, place the battery in a cool, dry place and wait for the
battery temperature to return to 35°C.
B. If the temperature change is more than 3°C and it continues to rise, submerse the battery in
salt water immediately.
C. If the temperature continues to rise when measuring it at 30 minute intervals, submerse the
battery in salt water immediately.
3. Isolation resistance check(using a MΩ tester)
(1) Measure the isolation resistance between the power relay terminal (+) and the battery pack
cover.
(2) Measure the isolation resistance between the power relay terminal (-) and the battery pack
cover.
▶ Criteria: 2MΩ or less (at 500V)
▶ Measures: Insulate the battery using insulating materials.
(Refer to "Take insulation actions for parts that may short circuit.)
4. Take insulation actions for parts that may short circuit(Visual inspection)
(1) High voltage battery – PRA cable terminal
(2) BMS voltage sensing connector
▶ Insulation actions
A. Use the insulation tape or rubber cap to prevent short circuit to the battery pack, cells,
modules.
B. Fix the connector terminal to prevent wiring from moving.
5. Electrolyte leakage check
A. Check for odors within 30cm of the battery pack (electrolyte odors like chemicals or acryl).
▶ Measures: Submerse the battery in salt water immediately if a smell is detected.
Damaged
battery
check
results:
normal
Damaged
battery
Damaged
battery
check
results:
abnormal
Storage
Remove the service disconnect plug and store the battery under the same conditions as a new
battery.
Transport Minimize impacts and ensure the battery does not come in contact with other parts.
Disposal
Transport the battery to the designated disposer; discharge it by submerging it completely in salt
water and carry out the disposal procedure.
Storage
Remove the service disconnect plug; insulate all exposed terminals; place the battery in a cool, dry
place away from volatile or combustible substances; use insulating materials (insulation tape, rubber
caps, etc.) or vinyl to wrap the battery; use anti-shock materials inside the box.
▶ Insulation action: Refer to "Take insulation actions for parts that may short circuit.
▶ Packing: Abnormal battery must be packed as same as a new battery.
Transport Minimize impacts and ensure the battery does not come in contact with other parts.
Disposal
Transport the battery to the designated disposer; discharge it by submerging it completely in salt
water and carry out the disposal procedure.
Voltage Check
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
1. Measure the voltage between the service disconnect plug upper (+) terminal and [High voltage battery –PRA] connecting cable (-) terminal.
Specification: 120 ~ 207 V
2. Measure the voltage between the service disconnect plug lower (-) terminal and [High voltage battery –PRA] connecting cable (+) terminal.
Specification: 120 ~ 207 V
Page 22 sur 245
3. Install the safety plug.
4. Measure the voltage between the high voltage battery (+) terminal and (-) terminal.
Specification: 240 ~ 413 V
Page 23 sur 245
Take insulation actions for parts that may short circuit
1. High voltage battery – PRA cable terminal
Page 24 sur 245
A. Wrap insulation tape or rubber cap around (+), (-) cable terminals to prevent short circuit of the battery pack.
B. Secure the cable to the battery pack case with the insulation tape to prevent cables from moving.
2. BMS voltage sensing connector
▶ Insulation actions
A. Wrap insulation tape or rubber cap around connectors to prevent short circuit of the battery cells and modules.
B. Secure the wiring to the battery pack case with the insulation tape to prevent wiring from moving.
Discharging high voltage batteries
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
High voltage batteries can cause electric shock or other injuries. If the following symptoms are detected in a high voltage battery, discharge it
as soon as possible by submerging it in salt water.
- There are traces of fire or smoke.
- The voltage of the battery is abnormally high (413 V or higher).
- The temperature of the high voltage battery continues to rises abnormally.
- It smells like chemicals or acrylic, a possible sign of electrolyte leakage.
[Discharging a battery by submersing it in salt water]
1. Pour about 53 gallons (200 liters) of water into a plastic container (e.g. poly propylene) that can submerge the whole battery.
2. Add 238 pounds (108kg) of salt to the water. Stir until salt dissolves into the solution.
Page 25 sur 245
[The amount of salt] = 0.538 * [The amount of water that a battery can be fully immersed]
3. Use a lift jack to submerge the high voltage battery in the salt water.
4. Leave the battery in the salt water for 12 hours before taking it out and drying it thoroughly.
The battery should be dried in a ventilated shade to avoid direct sunlight, snow and rain.
Put only one high voltage battery in a single salt water tank.
If you discharge more than one battery, put in the battery after discharging the previous battery completely to ensure safety.
If not, unexpected accidents such as burns may occur by exothermic reaction.
EV Battery System
Specification
High Voltage Shut-off Procedures
▷ Specification
Item
Specification
Remark
Capacitor Voltage between the inverter
terminals
Less than 30V
Checkable by multi tester
High Voltage Battery Handling Guide
▷ Specification
Item
Safety Plug Cable Resistance (Ω)
Specification
Less than 1Ω (20°C)
Remark
Checkable by multi tester
Main Fuse Resistance (Ω)
Less than 1Ω (20°C)
Checkable by multi tester
Checking for Welding in the High voltage
Main Relay
NO
Checkable by GDS
Checking for welding in the High Voltage
Main Relay
∞Ω(20°C)
Checkable by multi tester
Insulation Resistance Inspection (MΩ)
Insulation Resistance Inspection (MΩ)
300 ~ 1000
More than 2MΩ (20°C)
Checkable by GDS
Mega Ohm tester
Check the High Voltage Battery Voltage
(V)
[No. 1 Module ~ No. 4 Module or No.5
Module ~ No.8 Module]
120 ~ 207
Checkable by multi tester
Page 26 sur 245
240 ~ 413
Checkable by multi tester
Item
Specification
Note
Cell
96
-
Rated Voltage (V)
Capacity (Ah)
360
75
-
Check the High Voltage Battery Voltage
(V)
[No. 1 Module ~ No. 8 Module]
High Voltage Battery System
Energy (KWh)
27
-
Weight (kg)
203
-
Cooling System
Air-cooled
Forced air cooled
Note
Item
Specification
SOC (%)
5 ~ 95
Cell Voltage (V)
Pack Voltage (V)
2.5 ~ 4.3
240 ~ 413
Voltage difference between cells (mV)
Less than 40
Insulation resistance (KΩ)
Insulation resistance (MΩ)
300 ~ 1000
More than 2
Checkable by GDS
Mega Ohm tester
High Voltage Battery Control System
BMS ECU
▷ Specification
Item
C-CAN terminating resistance (Ω)
Specification
About 60
Remark
Combined resistance (BMS ECU↔Inverter)
C-CAN terminating resistnace (Ω)
About 120
BMS ECU resistance
Main Relay
▷ Specification
Item
ON
Coil
Specification
Rated Voltage (V)
Rated Ampere (A)
450
200
Voltage Drop (V)
Operation Voltage (V)
Less than 0.1 (200A)
12
Resistance (Ω)
21.6 ~ 26.4 (20°C)
Item
Specification
Note
Main Relay Fixing Status
NO
Checkable by GDS
Main Relay Switch (-) Resistance (Ω)
∞
Checkable by multi tester
Main Relay Operation Beep
"Clicking"
Checkable by GDS and SST
Coil Resistance (Ω)
21.6 ~ 26.4 (20°C)
Checkable by multi tester
Pre-Charge Relay
▷ Specification
Item
Specification
Rated Voltage(V)
ON
Coil
450
Rated Ampere(A)
10
Voltage Drop(V)
Less than 0.5 (10A)
Operation Voltage(V)
12
Resistance(Ω)
104.4 ~ 127.6 (20°C)
Item
Main Relay Switch (-) Resistance (Ω)
Specification
∞
Remark
Checkable by multi tester
Pre Charger Relay Operation Sound
"Clicking"
Checkable by GDS and SST
Page 27 sur 245
Pre Charger Relay Coil Resistance (Ω)
104.4 ~ 127.6 (20°C)
Checkable by multi tester
PRE-Charge Resistor
▷ Specification
Item
Coil
Capacity (W)
Specification
60
Resistance (Ω)
30
Battery Current Sensor
▷ Specification
Current (A)
Ouput Voltage (V)
-400(Charge)
-200 (Charge)
0.5
1.5
0
2.5
200 (Discharge)
3.5
+400 (Discharge)
4.5
Item
Current Sensor Ouput Voltage (V)
Specifications
About 2.5 ± 0.1
Remark
Checkable by multi tester
Current Sensor Power Voltage (V)
About 5 ± 0.1
Checkable by multi tester
Main Fuse
▷ Specification
Item
Specification
Rated Voltage (V)
Rated Current (A)
450 (DC)
250 (DC)
Item
Safety Plug Cable Resistance (Ω)
Specification
Less than 1 (20°C)
Remark
Checkable by multi tester
Main Fuse Resistance (Ω)
Less than 1 (20°C)
Checkable by multi tester
Battery Temperature Sensor
▷ Specification
Temperature (°C)
Resitance (KΩ)
Tolerance (%)
-40
204.5
±4.0
-30
- 20
117.8
70.34
±3.5
±3.0
- 10
0
43.43
27.63
±2.5
±2.0
10
18.07
±1.6
20
30
12.11
8.303
±1.2
±1.2
40
5.813
±1.5
50
4.149
±1.9
60
3.013
±2.2
70
2.225
±2.5
Runaway Arresting Device (RAD)
▷ Specification
Item
Specification
Remark
RAD Combined Resistance (Ω)
RAD Terminal Resistance (Ω)
Less than 3 (20°C)
Less than 0.375 (20°C)
Checkable by multi tester
Checkable by multi tester
RAD Switch Position
Bottom
RAD switch and visual inspection
High Voltage Battery Heater
▷ Specification
Page 28 sur 245
[14 Cell LH/ RH]
Item
Resistance (Ω)
Specification
26 ~ 29
Item
Resistance (Ω)
Specification
16 ~ 18
[10 Cell LH/ RH]
High Voltage Battery Heater Relay
▷ Specification
Item
Specification
Rated Voltage (V)
ON
Coil
450
Rated Current (A)
10
Voltage Drop (V)
Less than 0.5 (200A)
Operation Voltage (V)
12
Resistance (Ω)
104.4 ~ 127.6 (20°C)
Item
Specification
Remark
Heater Relay Switch Resistance (Ω)
Heater Relay Operation Sound
∞
"Tik", "Tok"
Checkable by multi tester
Checkable by GDS and SST
Heater Relay Coil Resistance (Ω)
104.4 ~ 127.6 (20°C)
Checkable by multi tester
High Voltage Battery Heater Fuse
▷ Specification
Item
Specification
Current (A)
10
High Voltage Battery Heater Temperature Sensor
▷ Specification
Temperature (°C)
Resistance (KΩ)
Tolerance (%)
-40
-30
204.5
117.8
±4.0
±3.5
- 20
- 10
70.34
43.43
±3.0
±2.5
0
27.63
±2.0
10
20
18.07
12.11
±1.6
±1.2
30
8.303
±1.2
40
5.813
±1.5
50
4.149
±1.9
60
3.013
±2.2
70
2.225
±2.5
High Voltage Battery Cooling System
Cooling Fan
▷ Specification
Duty(%)
Fan Speed(rpm)
0
0
0
1
10
900
2
3
20
30
1200
1500
4
5
40
50
1800
2100
6
60
2450
7
70
2600
Page 29 sur 245
8
80
2800
9
90
3000
Inlet Temperature Sensor
▷ Specification
Temperature (°C)
Resistance (KΩ)
Tolerance (%)
-40
-30
204.5
117.8
±4.0
±3.5
- 20
70.34
±3.0
- 10
43.43
±2.5
0
27.63
±2.0
10
18.07
±1.6
20
12.11
±1.2
30
8.303
±1.2
40
50
5.813
4.149
±1.5
±1.9
60
3.013
±2.2
70
2.225
±2.5
High Voltage Charging System
ON-Board Charger (OBC)
▷ Specification
Maximum Output
6.6kW
Ouput Density
Size
0.52kVA/ℓ
327 X 367 X 105 mm
ICCB
EVSE
About 1.4kW
6.6kW
100kW
DC 500V, 200A
50kW
DC 450V, 110A
▷ Specification
Tightening Torques
High Voltage Shut-off Procedures
Item
Safety plug service cover mounting nut
N.m
kgf.m
lb-ft
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
High Voltage Battery System
N.m
kgf.m
lb-ft
Ground cable mounting bolt
Item
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
High voltage battery system assembly mounting bolt
55.0 ~ 82.4
5.6 ~ 8.4
40.5 ~ 60.8
Safety plug cable assembly bracket mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
High voltage battery pack upper case mounting bolt
Battery module outlet duct mounting nut
7.8 ~ 11.8
7.8 ~ 11.8
0.8 ~ 1.2
0.8 ~ 1.2
5.8 ~ 8.7
5.8 ~ 8.7
Battery rear mounting bracket mounting bolt
High voltage positive (+) power cable mounting nut
7.8 ~ 11.8
7.8 ~ 11.8
0.8 ~ 1.2
0.8 ~ 1.2
5.8 ~ 8.7
5.8 ~ 8.7
High voltage negative (-) power cable mounting nut
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Inverter busbar mounting bolt/nut
Power relay assembly mounting nut
7.8 ~ 11.8
7.8 ~ 11.8
0.8 ~ 1.2
0.8 ~ 1.2
5.8 ~ 8.7
5.8 ~ 8.7
BMS ECU mounting nut
Safety plug cable assembly mounting nut
7.8 ~ 11.8
7.8 ~ 11.8
0.8 ~ 1.2
0.8 ~ 1.2
5.8 ~ 8.7
5.8 ~ 8.7
5.8 ~ 8.7
BMS extension wiring mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
Ground bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
High voltage connector mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Page 30 sur 245
High voltage battery pack assembly mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Safety plug cable assembly bracket mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Item
High voltage power (+)(-)cable mounting nut
N.m
7.8 ~ 11.8
kgf.m
0.8 ~ 1.2
lb-ft
5.8 ~ 8.7
Safety plug cable assembly bracket mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
High voltage battery pack upper case mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
BMS ECU mounting nut
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Safety plug service cover mounting nut
Safety plug cable assembly bracket mounting nut
7.8 ~ 11.8
7.8 ~ 11.8
0.8 ~ 1.2
0.8 ~ 1.2
5.8 ~ 8.7
5.8 ~ 8.7
Item
Protector outlet duct panel mounting nut
N.m
7.8 ~ 11.8
kgf.m
0.8 ~ 1.2
lb-ft
5.8 ~ 8.7
Outlet cooling duct mounting bolt
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Cooling fan mounting nut
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Battery module outlet duct mounting nut
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
N.m
9.8 ~ 11.8
kgf.m
1.0 ~ 1.2
lb-ft
7.2 ~ 8.7
High Voltage Battery Control System
High Voltage Battery Cooling System
High Voltage Charging System
Item
OBC mounting bolt
Normal charge port mounting bolt
10.8 ~ 13.7
1.1 ~ 1.4
8.0 ~ 10.1
Rapid charge port mounting bolt
10.8 ~ 13.7
1.1 ~ 1.4
8.0 ~ 10.1
High Voltage Distributing System
N.m
kgf.m
lb-ft
High voltage joint box mounting bolt
Under cover mounting bolt/ nut
Item
7.8 ~ 11.8
7.8 ~ 11.8
0.8 ~ 1.2
0.8 ~ 1.2
5.8 ~ 8.7
5.8 ~ 8.7
Protector bracket mounting nut
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Cable protect mounting nut
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
EV Battery System
Components Location
Page 31 sur 245
1. High Voltage Battery System Assembly
2. Electronic Power Control Unit (EPCU)
[LDC+Inverter+VCU]
3. ON-Board Charger (OBC)
4. High Voltage Joint Box
5. High Voltage Cable
6. Motor Assembly
7. Reduction
EV Battery System
Description and Operation
Electric vehicle is powered by transforming electric energy into kinetic energy in the motor and high voltage battery. It can be recharged by
high voltage energy via IBC or OBC. Electric motor not only has the role of driving the vehicle but also acts as an alternator to generate
electric energy used to recharge the high voltage battery by regenerative braking. Operation principles among modules are as detailed below.
Page 32 sur 245
High Voltage Electricity Flow Diagram
[Start/ Acceleration/ Uphill Take-off]
Page 33 sur 245
Electric energy stored in high voltage battery pack assembly is used to generate drive force from the drive motor. Electric energy is
transformed into kinetic energy and drive force is transferred to the wheels.
[Deceleration (Regenerative Braking)]
Page 34 sur 245
- Drive motor is used as an alternator and uses the kinetic energy generated during deceleration to recharge electric energy in the high
voltage battery pack assembly.
- Activate: When the vehicle speed is over 10 km/h
- Not Activate: When the vehicle speed is less than 3 km/h
[Rapid Charge]
Page 35 sur 245
- Charge power : 500V, 200A
- Charge Type : Direct Current (DC)
- Charge time: Approx. 25 min.
- Charge Flow Diagram : Rapid Charge Stand -> High Voltage Battery System Assembly
- Charge Volume: 80% of High Voltage Battery's SOC
[Nomal Charge]
Page 36 sur 245
- Charge power: 220V, 35A
- Charge Type : Alternating Current (AC)
- Charge time: Approx. 5 hr.
- Charge Flow Diagram : Normal Charge Stand -> ON-Board Charger (OBC) -> High Voltage Battery System Assembly
- Charge Volume : 95 % of High Voltage Battery's SOC
[Indicator]
Page 37 sur 245
NO
RefSymbol
Name
Description
Operation
Signal
Control unit
power
Input
Color
Illumination
Green
LED
CAN
VCU
IGN1
Green
LED
CAN
BMS
IGN3
Red
LED
CAN
BMS
IGN3
Yellow
LED
CAN
VCU
IGN1
VCU
MCU
BMS
LDC
FATC
IGN1
OBC
IG1 &
IGN3
BMS
IGN1
Request ON when vehicle is
ready for driving.
1
2
Ready lamp
Charge
Lamp
Request to turn ON indication
Lamp when charging is
complete.
Request to turn ON indication
Lamp when charging is in
progress.
3
Charge
Lamp
4
In case of fault as indicated
below, vehicle power output is
limited, and Lamp ON is
requested.
Power Down - Overheating, or low SOC
Lamp
- Overheating and system error
- If vehicle speed is limited due
to ABS or brake system failure.
- Cooling system failure
5
6
Service
Lamp
- Request ON in case of VCU,
MCU, BMS, LDC, FATC, or
OBC failure is detected.
- Turns ON at Start and then
OFF after 3 seconds.
Yellow
Yellow
LED
LED
CAN
CAN
Page 38 sur 245
LOW Battery Request Lamp ON when high
Lamp
voltage battery SOC is low.
7
8
EV Battery System
System Diagram
In case of 12V auxiliary battery
Auxiliary 12V discharged, recharge device
failure, or recharge system
Battery
failure.
Charge
Lamp
Warning Lamp ON Request
RES Lamp Request ON in case of
regenerative brake failure.
(RBS:
Regenerative
Braking
System)
Red
LED
CAN
LDC
IGN1
Yellow
LED
CAN
EBS
IGN1
Page 39 sur 245
OBC: ON-Board Charger
QRA: Quick Charge Relay Assembly
PRA: Power Relay Assembly
EWP: Electronic Water Pump
EPCU: Electronic Power Control Unit [LDC + Inverter + VCU]
EV Battery System
Special Service Tools
Tool Name / Number
High Voltage Cable
0K918-E4100
Illustration
Description
Used for measuring the high voltage battery system
BMS Check Connector (21pin)
0K375-E4100
Used for measuring the high voltage battery system
BMS Check Connector (8pin)
0K375-E4200
Used for measuring the high voltage battery system
Insulated tool set
0K375-4U000
Used for measuring or work to high voltage parts
-22EA components (Include case)
HV Battery assembly lifting fixture
0K375-E4300
Removing and installing battery pack assembly
Page 40 sur 245
No.
Tool Name
Tool Number
1
2
Insulated Flat Head Screwdriver-6"
Insulated Phillips Screwdriver-6"
0K375-4U100
0K375-4U110
3
Insulated Flat Head Screwdriver-4"
0K375-4U120
4
5
Insulated Phillips Screwdriver-4"
Insulated Spanner-8mm
0K375-4U130
0K375-4U140
6
Insulated Spanner-10mm
0K375-4U150
7
8
Insulated Spanner-12mm
Insulated Spanner-12mm
0K375-4U160
0K375-4U170
9
Insulated Spanner-17mm
0K375-4U180
10
Insulated Ratchet Wrench-3/8"
0K375-4U190
11
Insulated Ratchet Wrench-3/8"
0K375-4U200
12
Insulated Socket Extension Bar-3/8"
0K375-4U210
13
Insulated Socket-8mm
0K375-4U220
14
Insulated Socket-10mm
0K375-4U230
15
Insulated Socket-12mm
0K375-4U240
16
Insulated Socket-14mm
0K375-4U250
17
18
Insulated Socket-17mm
Insulated Socket-19mm
0K375-4U260
0K375-4U270
19
Insulated Nippers-6"
0K375-4U280
20
21
Insulated Pliers-8"
Insulated Cutter
0K375-4U290
0K375-4U300
22
Insulated Tool Box
0K375-4U310
Personal Protective Equipment
Page 41 sur 245
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• When removing, installing or inspecting the high voltage
battery terminals or wiring where spark may happen.
• When working on high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
Any removed high voltage components are placed on the
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used to inform danger above this line.
Page 42 sur 245
Commercial Tool
Tool Name
Battery lift table
Illustration
Description
Removing and installing battery pack assembly
pack weight: 277 kg
pack size: 1647mm x 996mm x 261mm
Multi tester
Measuring resistance, voltage, and resistance
Insulation resistance tester(Multi tester)
Measuring insulation resistance, voltage, and
resistance
Crane jack
Removing and installing battery pack assembly
pack weight: 277 kg
pack size: 1647mm x 996mm x 261mm
EV Battery System
Basic Troubleshooting
Basic Inspection Procedure
Measuring Condition of Electronic Parts' Resistance
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient
temperature (20°C, 68°F), unless stated otherwise.
The measured resistance to temperature other than ambient temperature (20°C, 68°F) is for reference only.
Intermittent Problem Inspection Procedure
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An example
would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician should thoroughly
make out a "Customer Problem Analysis Sheet" and recreate (simulate) the environment and condition which occurred when the vehicle was
having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins, and then verify that the
connectors are always securely fastened.
Page 43 sur 245
3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
● Simulating Vibration
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
Strong vibration may break sensors, actuators or relays
2) Connectors and Harness
: Lightly shake the connector and wiring harness vertically and then horizontally.
● Simulating Heat
1) Heat components suspected of causing the malfunction with a hair dryer or other heat source.
• DO NOT heat components to the point where they may be damaged.
• DO NOT heat the ECM directly.
● Simulating Water Sprinkling
1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
DO NOT sprinkle water directly into the engine compartment or electronic components.
● Simulating Electrical Load
1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger, etc.).
Connector Inspection Procedure
1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
Page 44 sur 245
B. When removing the connector with a lock, press or pull locking lever.
C. Listen for a click when locking connectors. This sound indicates that they are securely locked.
D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side.
E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side.
• Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the tester lead.
2. Checking Point for Connector
A. While the connector is connected:
Page 45 sur 245
Hold the connector, check connecting condition and locking efficiency.
B. When the connector is disconnected:
Check for missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
C. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
3. Repair Method of Connector Terminal
A. Clean the contact points using air gun and/or shop rag.
Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.
B. In case of abnormal contact pressure, replace the female terminal.
Wire Harness Inspection Procedure
1.
2.
3.
4.
5.
6.
Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
Check whether the wire harness is twisted, pulled or loosened.
Check whether the temperature of the wire harness is abnormally high.
Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
Check the connection between the wire harness and any installed part.
If the covering of wire harness is damaged; secure, repair or replace the harness.
Electrical Circuit Inspection Procedure
● Check Open Circuit
1. Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check
Method) as shown below.
2. Continuity Check Method
When measuring the resistance, lightly shake the wire harness up and down or left to right.
Specification (Resistance)
1Ω or less → Normal Circuit
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1MΩ or Higher → Open Circuit
A. Disconnect connectors (A), (C) and measure resistance between connectors (A) and (C) as shown in [FIG. 2].
In [FIG.2.] the measured resistance of lines 1 and 2 is higher than 1MΩ and below 1 Ω respectively. Specifically, the open circuit is line
1 (Line 2 is normal). To find the exact break point, check sub line of line 1 as described in the following step.
B. Disconnect connector (B), and measure the resistance between connectors (C) and (B1) and between (B2) and (A) as shown in [FIG.
3].
In this case the measured resistance between connectors (C) and (B1) is higher than 1MΩ and the open circuit is located between
terminal 1 of connector (C) and terminal 1 of connector (B1).
3. Voltage Check Method
A. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each connectors (A), (B) and
(C) as shown in [FIG. 4].
The measured voltages of each connector are 5V, 5V and 0V respectively. So the open circuit is located between connectors (C) and
(B).
● Check Short Circuit
1. Test Method for Short to Ground Circuit
A. Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2 (Continuity Check Method with
Chassis Ground) as shown below.
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2. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness up and down or left to right when measuring the resistance.
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit
A. Disconnect connectors (A), (C) and measure the resistance between connector (A) and Chassis Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively. Specifically, the short to
ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of line 1 as described in the following step.
B. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis
ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is between terminal 1
of connector (C) and terminal 1 of connector (B1).
● Testing For Voltage Drop
This test checks for voltage drop along a wire or through a connection or a switch.
1) Connect the positive lead of a voltmeter to the end of the wire (or to the side of the connector or switch) closest to the battery.
2) Connect the negative lead to the other end of the wire. (or the other side of the connector or switch)
3) Operate the circuit.
4) The voltmeter will show the difference in voltage between the two points. A difference, or drop of more than 0.1 volts (50mV in 5V circuits),
may indicate a problem. Check the circuit for loose or dirty connections.
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EV Battery System
Components
High Voltage Battery System Assembly
1. High Voltage Battery System Assembly
2. High Voltage Battery Pack Assembly
3. PRA (Power Relay Assembly)
4. Case
5. QRA (Quick Charge Relay Assembly)
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EV Battery System
Description
High Voltage Battery System Assembly
- To provide the 360V high voltage electric energy to electric motor
- To save the electric energy generated by regenerative braking system
- Charged by rapid charge or normal charge
High Voltage Battery Pack Assembly
Type : Lithium Ion Polymer
Cell : Minimum unit which saves the electric energy converted from the chemical energy
Module : A number of cells in series
Pack : A number of modules in series
EV Battery System
System Diagram
High Voltage Battery System Assembly
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System Circuit Diagram
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EV Battery System
Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200.
[Battery Pack Assembly Inspection]
Disconnection
Rust
Specification
Method
Countermeasure
-
Visual check
-
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Discolor
Installation status
Leak
DTC about BMS ECU
SOC
Voltage
Refer to DTC guide
5% ~ 95%
Cell
2.5 ~ 4.3 V
Pack
240 ~ 413 V
Difference
between cells
less than 40mV
300KΩ ~ 1000KΩ
Insulation resistance
Refer to DTC guide
Check the "Current Data" by Check the battery voltage sensing circuit (Refer to
GDS
"Battery voltage sensing circuit")
Check the "Current Data" by
GDS
more than 2MΩ
Using mega ohm tester
more than 2MΩ
Using mega ohm tester
SOC (State Of Charge) - The percentage of battery charging status
[Visual Inspection]
Item - Electric System, Cooling System, High Voltage Battery Pack Assembly
Problem - Disconnection, Rust, Component status, Oil leak
[SOC Inspection ]
1.
2.
3.
4.
Turn the ignition OFF.
Connect the GDS to DLC.
Turn the ignition ON.
Check the SOC in the GDS service data.
SOC: 5 ~ 95 %
[Battery Voltage Inspection]
1. Turn the ignition OFF.
2. Connect the GDS to DLC.
Refer to DTC guide
Check the "Current Data" by Refer to "SOC level and the countermeasure
GDS
Refer to "Insulation resistance circuit"
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3. Turn the ignition ON.
4. Check the Cell Voltage and the Pack Voltage in the GDS service data.
Cell Voltage : 2.5 ~ 4.3 V
Pack Voltage: 240 ~ 413 V
Voltage gap between cells : Less than 40 mV
[Voltage sensing circuit Inspection]
1. Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Battery Pack Assembly")
2. Remove the wiring harness of the voltage & temperature sensor.
(Refer to High Voltage Battery System - Repair procedures - Disassembly - "Wiring harness of the voltage & temperature sensor")
3. Perform the current test of battery module and the BMS ECU connector.
Specified value :Less than 1Ω (20°C)
4. Install the BMS ECU to lower case.
5. Install the wiring harness of voltage & temperature sensor to BMS ECU.
6. Measure the insulation resistance between the battery module harness and the lower case.
Specifed value :More than 1MΩ (20°C)
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[Insulation Resistance Inspection (With vehicle)]
The insulation status between the vehicle and the battery pack assembly can be checked by GDS or measuring the resistance.
[GDS - Service data]
1. Turn the ignition switch OFF.
2. Connect the GDS to DLC.
3. Turn the ignition switch ON.
4. Inspect the insulation resistance in the GDS service data.
Specified value :300kΩ ~ 1000kΩ
[By using the Mega Ohm Tester]
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shout-off Procedure")
2. Connect the negative (-) terminal of mega ohm meter (A) to ground of the vehicle.
For precise measuring, connect the negative (-) terminal to the parts not painted.
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3. After connecting the positive (+) terminal to positive (+) terminal of the battery, measure the resistance as follows.
[Insulation resistance of positive (+) terminal of the battery pack assembly
(1) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) Check the resistance.
Specified value : More than 2MΩ (20°C)
4. After connecting the positive (+) terminal to negative (-) terminal of the battery, measure the resistance as follows.
[Insulation resistance of negative (-) terminal of the battery pack assembly]
(1) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) Check the resistance.
Specified value : More thanSpecified value : More than 2MΩ (20°C)
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[Insulation Resistance Inspection (With battery)]
[By using the Mega Ohm Tester]
1. Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Battery Pack Assembly")
2. Remove the upper case of high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Case")
3. Remove the protect cover (A) of power relay assembly (PRA).
4. Connect the negative (-) terminal of mega ohm meter to lower case.
For precise measuring, connect the negative (-) terminal to the parts not painted.
5. Connect the positive (+) terminal to high voltage battery terminals to measure the resistance.
[Insulation resistance of positve (+) terminal of PRA high voltage]
(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA high voltage.
(2) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) Check the reistance value.
Specified value : More than 2MΩ (20°C)
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[Insulation resistance of negative (-) terminal of PRA high voltage]
(1) Connect the positive (+) terminal of mega ohm meter (B) to negative (-) terminal of PRA high voltage.
(2) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) Check the reistance value.
Specified value : More than 2MΩ (20°C)
[Insulation resistance of positive (+) terminal of PRA inverter power]
(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA inverter power.
(2) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) Check the reistance value.
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Specified value : More than 2MΩ (20°C)
[Insulation resistance of positive (-) terminal of PRA inverter power]
(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (-) terminal of PRA inverter power.
(2) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3) Check the reistance value.
Specified value : More than 2MΩ (20°C)
EV Battery System
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Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1.
2.
3.
4.
Turn the ignition swtich OFF and disconnect the auxiliary battery negative (-) terminal.
Shut off the high voltage. ("Refer to "High Voltage Shut-off Procedure")
Lift the vehicle.
After loosening the nut, remove the high voltage battery front under cover (A).
5. After loosening the nut, remove the high voltage rear under cover (A).
6. Disconnect the BMS connector (A).
7. Disconnect the high voltage cable (A).
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8. Disconnect the ground cable (B) by loosening the mounting bolt (A).
Ground cable mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
9. Support the high voltage battery pack assembly with the jack (A).
• Securely support the battery pack assembly with a jack to prevent any accidents.
• Confirm that high voltage cable & connectors are completely removed before removing the battery pack assembly.
• Place rubber on the jack to protect the lower part of the battery pack and the stud bolts used to tighten the under cover.
10. Loosen the high voltage battery system assembly mounting bolt (A).
High voltage battery system assembly mounting bolt:54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)
[Front]
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[Right]
[Left]
[Back]
11. Remove the high voltage battery system assembly (A) from the vehicle.
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Disassembly
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Battery Pack Assembly - Repair procedures - "Removal")
2. Remove the ground cable (B) by loosening the mounting bolt (A).
[Right]
[Left]
3. Remove the safety plug cable assembly bracket mounting bolt (A).
Safety plug cable assembly bracket mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. After loosening the mounting bolt, remove the upper case (A).
High voltage battery pack upper case mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
5. Remove the waterproof gasket (A).
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6. Disconnect the RAD wiring connector (A).
[Right]
[Back]
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[Left]
7. After loosening the mounting nut, remove the battery module outlet duct (A).
Battery module outlet duct mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
8. After loosening the mounting bolt, remove the bracket (A).
Battery rear mounting bracket mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
9. Remove the high voltage power cable cover (A).
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10. After loosening the mounting nut (A), remove the high voltage positive (+) power cable (B)
High voltage positive (+) power cable mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
11. After loosening the mounting nut (A), remove the high voltage negative (-) power cable (B).
High voltage negative (-) power cable mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
12. Remove the inverter busbar cover (A).
13. Remove the inverter busbar (A).
Inverter busbar mounting bolt/nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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14. Disconnect the high voltage battery heater system control positive (+) power and the ground connetor (A). [With high voltage battery
heater system]
15. Dsiconnect the power relay assembly connector (A).
16. After loosening the mounting nut, remove the power relay assembly (A).
Power relay assembly mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
17. Disconnect the BMS ECU connector (A).
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18. After loosening the mounting nut, remove the BMS ECU (A).
BMS ECU mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
19. Disconnect the safety plug interlock connector (A).
20. After loosening the mounting nut (A), remove the safety plug cable assembly (B).
Safety plug cable assembly mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
21. Loosen the BMS extension wiring mounting bolt (A).
BMS extension wiring mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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22. After loosening the ground bolt (A), remove the BMS extension wiring (B).
Ground bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
23. After disconnecting the interlock switch connector (A) and loosening the mounting bolt (B), remove the high voltage connector (C).
High voltage connector mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
24. Remove the high voltage battery pack assembly.
(1) Remove the high voltage battery pack assembly mounting bolt.
High voltage battery pack assembly mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
(2) Install the SST No. 0K375-E4300 (A) in battery pack assembly as shown in the image below.
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Be sure to screw the eye bolts to the holes firmly not to allow the bolts to be loosened while lifting the battery pack assembly
using a crane jack.
(3) Install the SST No. OK375-E4300 (A) to crane jack.
(4) Install the SST No. OK375-E4300 & crane jack (A).
• Make sure that the hanger hooks and the eye bolts aligns.
• Adjust the hanger main frame to fit the size of the battery pack assembly.
(5) Remove the high voltage battery pack assembly (A).
Make sure that the battery pack assembly is balanced.
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The battery pack assembly is divided into LH / RH battery pack so be sure to remove the battery one by one. The order of removal
is not important.
25. After loosening the harness mounting screw, remove the voltage & temperature sensor wiring harness (A) from the battery pack
assembly.
[LH]
[RH]
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A/S unit
BMS ECU
Refer to High Voltage Battery Control System - "BMS ECU"
High Voltage Battery Pack Assembly
Refer to High Voltage Battery System - "Battery Pack Assembly"
Power Relay Assembly (PRA)
Refer to High Voltage Battery System - "Power Relay"
Inverter Busbar
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1. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
2. Remove the inverter busbar cover (A).
3. Remove the inverter busbar (A).
Inverter busbar mounting bolt/nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
BMS Wiring Harness
1. Remove the BMS ECU
(Refer to High Voltage Battery Control System - "BMS ECU")
2. Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly")
3. Loosen the BMS extension wiring mounting bolt (A).
BMS extension wiring mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. After loosening the mounting bolt (A), remove the BMS extension wiring (B).
Ground bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Safety Plug Cable
Refer to High Voltage Battery Control System - Safety Plug - "Safety Plug Cable"
Front Case Left Panel
1. Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly")
2. Remove the front case left panel.
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Safety Plug Bracket
1. Shut off the high voltage.
(Refer to High Voltage Battery Control System - "High Voltage Shut-off Procedure")
2. After loosening the mounting bolt (A), remove the safety plug bracket (B).
High Voltage Connector Assembly
1. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2. After disconnecting the interlock switch connector (A) and loosening the mounting bolt (B), remove the high voltage connector (C).
High voltage connector mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Battery Rear Mounting Bracket
1. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2. After loosening the mounting nut, remove the battery module outlet duct (A).
Battery module outlet duct mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
3. After loosening the mounting bolt (A), remove the bracket (B).
Battery rear mounting bracket bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Watertight Rainforcement Bracket
1. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repair procedures - "Removal")
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2. After loosening the mounting bolt & nut, remove the watertight rainforcement bracket (A).
High Voltage Battery System Rear Mounting Bracket
1. Lift the vehicle.
2. Loosen the high voltage battery system rear mounting bracket bolt (A).
High voltage battery system rear mounting bracket bolt :54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)
3. Loosen the rear mounting bolt (A).
High voltage battery system rear mounting bracket bolt :54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)
4. Remove the high voltage battery system rear mounting bracket (A).
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Battery Voltage & Temperature Sensor Wiring Harness
1. Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "High Voltage Battery Pack Assembly")
2. After loosening the harness mounting screw, remove the voltage & temperature wiring harness (A) from the high voltage battery pack
assembly.
[LH]
[RH]
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High Voltage Positive (+) Power Cable
1. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2. Disconnect the high voltage power cable cover (A).
3. After loosening the mounting nut, remove the high voltage positive (+) power cable (A).
High voltage positive (+) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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High Voltage Negative (-) Power Cable
1. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2. Disconnect the high voltage power cable cover (A).
3. After loosening the mounting nut, remove the high voltage negative(-) power cable (A).
High voltage negative (-) power cable mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Battery Module Outlet Duct
1. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2. After loosening the mounting nut, remove the battery module outlet duct (A).
Battery module outlet duct mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Safety Plug
Refer to High Voltage Battery Control System - "Safety Plug"
High Voltage Battery Pack Lower Case
Refer to High Voltage Battery System - Case - "Lower Case"
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High Voltage Battery Pack Upper Case
Refer to High Voltage Battery System - Case - "Upper Case"
Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When installing the RAD harness, be sure to check if the connector is installed on the correct position.
[If not correct]
1. Failure of precharging
2. RAD malfunction (misrecognize that the high voltage battery is swollen)
[Main inspection items]
1. Check if the RAD switch faces down.
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2. Be careful not to reverse battery No. 1 module RAD connector (2 pins) and the BMS extension connector (1 pin) when assembling.
3. Be careful not to reverse battery No. 8 module RAD connector ( 2 pins) and the BMS extension connector (1 pin) when assembling.
1. Install the high voltage battery system and the related parts in the reverse order of removal.
EV Battery System
Specification
Item
Specification
Cell
96
Note
-
Rated Voltage (V)
360
2 Cells are parallel connected
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Capacity (Ah)
75
Energy (KWh)
27
-
Weight (kg)
Cooling System
203
Air-cooled
Forced air cooled
Item
SOC (%)
Specification
5 ~ 95
Note
Cell Voltage (V)
2.5 ~ 4.3
Pack Voltage (V)
Voltage difference between cells (mV)
240 ~ 413
Less than 40
Insulation resistance (KΩ)
Insulation resistance (MΩ)
300 ~ 1000
More than 2
Checkable by GDS
Mega Ohm tester
EV Battery System
Components
Without High Voltage Heater System
1. High Voltage Battery Pack Assembly
2. Runaway Arresting Device (RAD)
3. Busbar
4. Inlet Temperature Sensor
5. Voltage & Temperature Sensor Wiring Harness
6. Bolt
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With High Voltage Heater System
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1. High Voltage Battery Pack Assembly
2. Runaway Arresting Device (RAD)
3. Busbar
4. Inlet Temperature Sensor
5. Voltage & Temperature Sensor Wiring Harness
6. Bolt
7. High Voltage Battery Heater
8. High Voltage Battery Heater Temperature Sensor
EV Battery System
Inspection
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
[SOC Inspection ]
1.
2.
3.
4.
Turn the ignition OFF.
Connect the GDS to DLC.
Turn the ignition ON.
Check the SOC in the GDS service data.
SOC:5% ~ 95%
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[Battery Voltage Inspection]
1.
2.
3.
4.
Turn the ignition OFF.
Connect the GDS to DLC.
Turn the ignition ON.
Check the Cell Voltage and the Pack Voltage in the GDS service data.
Cell Voltage:2.5V ~ 4.3V
Pack Voltage:240V ~ 413V
Voltage gap between cells :Less than 40 mV
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[Insulation Resistance Inspection (By using the GDS)]
1. Turn the ignition switch OFF.
2. Connect the GDS to DLC.
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3. Turn the ignition switch ON.
4. Inspect the insulation resistance in the GDS service data.
Specified value:300KΩ ~ 1000KΩ
[Insulation Resistance Inspection (By using the Mega Ohm Tester)]
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shout-off Procedure")
2. Connect the negative (-) terminal of mega ohm meter (A) to ground of the vehicle.
For precise measuring, connect the negative (-) terminal to the parts not painted.
3. After connecting the positive (+) terminal to positive (+) terminal of the battery, measure the resistance as follows.
(1) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) Check the resistance.
Specified value : More than 2MΩ (20°C)
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4. After connecting the positive (+) terminal to negative (-) terminal of the battery, measure the resistance as follows.
(1) Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2) Check the resistance.
Specified value : More than 2MΩ (20°C)
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Battery Pack Assembly - Repair procedures - "Removal")
2. Remove the safety plug cable assembly bracket mounting bolt (A).
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Safety plug cable assembly bracket mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
3. After loosening the mounting bolt, remove the upper case (A).
High voltage battery pack upper case mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Disconnect the RAD wiring connector (A).
[Right]
[Back]
[Left]
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5. After loosening the mounting nut, remove the battery module outlet duct (A).
Battery module outlet duct mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
6. After loosening the mounting bolt, remove the bracke (A).
Battery rear mounting bracket mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
7. Remove the high voltage power cable cover (A).
8. After loosening the mounting nut (A), remove the high voltage positive (+) power cable (B)
High voltage positive (+) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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9. After loosening the mounting nut (A), remove the high voltage negative (-) power cable (B).
High voltage negative (-) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
10. Remove the inverter busbar cover (A).
11. Remove the inverter busbar (A).
Inverter busbar mounting bolt/nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
12. Disconnect the high voltage battery heater system control positive (+) power and the ground connector (A).
[With high voltage battery heater system]
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13. Dsiconnect the power relay assembly connector (A).
14. After loosening the mounting nut, remove the power relay assembly (A).
Power relay assembly mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
15. Disconnect the BMS ECU connector (A).
16. After loosening the mounting nut, remove the BMS ECU (A).
-BMS ECU mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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17. Disconnect the safety plug interlock connector (A).
18. After loosening the mounting nut (A), remove the safety plug cable assembly (B).
Safety plug cable assembly mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
19. After loosening the ground bolt (A), remove the BMS extension wiring (B).
Ground bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
20. Remove the high voltage battery pack assembly.
(1) Remove the high voltage battery pack assembly mounting bolt.
High voltage battery pack assembly mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
(2) Install the SST No. 0K375-E4300 (A) in battery pack assembly as shown in the image below.
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Be sure to screw the eye bolts to the holes firmly not to allow the bolts to be loosened while lifting the battery pack assembly
using a crane jack.
(3) Install the SST No. OK375-E4300 (A) to crane jack.
(4) Install the SST No. OK375-E4300 & crane jack (A).
• Make sure that the hanger hooks and the eye bolts align.
• Adjust the hanger main frame to fit the size of the battery pack assembly.
(5) Remove the high voltage battery pack assembly (A).
Make sure that the battery pack assembly is balanced.
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The battery pack assembly is divided into LH / RH battery pack so be sure to remove the battery one by one. The order of removal
is not important.
21. After loosening the harness mounting screw, remove the voltage & temperature sensor wiring harness (A) from the battery pack
assembly.
[LH]
[RH]
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Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When installing the RAD harness, be sure to check if the connector is installed on the correct position.
[If not correct]
1. Failure of precharging
2. RAD malfunction (misrecognize that the high voltage battery is swollen)
[Main inspection items]
1. Check if the RAD switch faces down
2. Be careful not to reverse battery No. 1 module RAD connector (2 pins) and the BMS extension connector (1 pin) when assembling.
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3. Be careful not to reverse battery No. 8 module RAD connector ( 2 pins) and the BMS extension connector (1 pin) when assembling.
1. Install the high voltage battery pack assembly in the reverse order of removal.
EV Battery System
Description
Power relay assembly (PRA) is installed in the high voltage battery system assembly and it consists of main relays which control the high
voltage, pre-charge relay, pre-charge resister and battery current sensor. PRA controls high voltage of 360V between the high voltage battery
pack and the high voltage joint box by BMS ECU control signal.
Operation
EV Battery System
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Remove the high voltage battery assembly.
(Refer to High Voltage Battery System - Battery Pack Assembly - Repair procedures - "Removal")
2. Loosen the safety plug cable assembly bracket mounting bolt (A).
Safety plug cable assembly bracket mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
3. After loosening the mounting bolt, remove the high voltage battery pack upper case (A).
High voltage battery pack upper case mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the high voltage power cable cover (A) and the inverter busbar cover (B).
5. After loosening the mounting nut (A), remove the high voltage positive (+) power cable (B).
High voltage positive (+) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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6. After loosening the mounting nut (A), remove the high voltage negative (-) power cable (B).
High voltage negative (-) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
7. Remove the inverter busbar (A).
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)Inverter busbar mounting bolt/nut : 0.8 ~ 1.2 kgf.m
8. Disconnect the high voltage battery heater system control positive (+) power and the ground connector (A).
[With the high voltage battery heater system]
9. Disconnect the power relay assembly connector (A).
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10. After loosening the mounting nut (A), remove the power relay assembly (B).
Power relay assembly mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Install the power relay assembly in the reverse order of removal.
EV Battery System
Description
Quick Charge Relay Assembly (QRA) is installed in the high voltage joint box and it consists of main relays which control the high voltage. The
QRA controls the high voltage between the high voltage battery pack and the high voltage joint box by BMS control signal. If the QRA
operates, the PRA operates too.
[Main Function]
1. During rapid charge, it acts as a switch that supplies high voltage to the battery pack.
2. The role of preventing the overcharge
Operation
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EV Battery System
Removal
QRA is integrated into the high voltage joint box and so each part cannot be replaced separately. Refer to removal procedure of high
voltage joint box.
Installation
QRA is integrated into the high voltage joint box and so each part cannot be replaced separately. Refer to removal procedure of high
voltage joint box.
EV Battery System
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
[Upper Case]
1. Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "High Voltage Battery Pack Assembly")
2. Loosen the safety plug cable assembly bracket mounting bolt (A).
Safety plug cable assembly bracket mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
3. After loosening the mounting bolt, remove the battery pack upper case (A).
High voltage battery pack upper case mounting bolt/nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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[Lower Case]
1. Disassemble the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repair procedrues - "Disassembly")
Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Install the case in the reverse order of removal.
EV Battery System
Components Location
High Voltage Battery System Assembly
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1. BMS ECU
2. Main Relay
3. Pre Charge Relay
4. Pre Charge Resistor
5. Battery Current Sensor
6. Safety Plug
7. Main Fuse
8. Battery Temperature Sensor
9. Runaway Arresting Device (RAD)
10. High Voltage Battery Heater (With heater system)
11. High Voltage Battery Heater Relay (With heater system)
12. High Voltage Battery Heater Fuse (With heater system)
13. High Voltage Battery Heater Temperature Sensor (With heater
system)
1. BMS ECU
2. Main Relay
3. Pre Charge Relay
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4. Pre Charge Resistor
5. Battery Current Sensor
6. Safety Plug
7. Main Fuse
8. Battery Temperature Sensor
9. Runaway Arresting Device (RAD)
10. High Voltage Battery Heater Temperature Sensor
11. High Voltage Battery Heater Fuse
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Power Relay Assembly (Without heater system)
1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
4. Pre Charge Resistor
5. Battery Current Sensor
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Power Relay Assembly (With heater system)
1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
4. Pre Charge Resistor
5. Battery Current Sensor
6. High Voltage Battery Heater Relay
7. High Voltage Battery Heater Fuse
EV Battery System
Description
High Voltage Battery Control System
High voltage battery control system consists of BMS ECU, PRA and it controls SOC (State of charge), output, trouble shooting, battery cell
balancing, cooling, power supply & disconnect.
Power Relay Assembly (PRA) consists of main relay, precharge relay, precharge resister, battery current sensor and battery heater relay. It is
connected to battery pack through busbar.
[Main Function]
Purpose
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SOC control
• Calculation of SOC by measuring the voltage/current/temperature
Battery ouput control
• Battery protection, Prediction of available power, Prevention of overcharge/overdischarge by
calculating the input/output energy as the system status
PRA control
• Cut off the power to the high voltage system when IG ON/OFF
• Prevent the safety accidents due to high voltage system failure
Cooling control
Trouble shooting
(Refer to "Trouble shooting")
• Maintain the battery temperature by controlling the cooling fan
• System troubleshooting, data monitoring and software management
• Limit the output by Fail-Safe
• Prevent the safety accidents by controlling the relay
• SOC (State Of Charge): Available energy in the battery
• SOC = [Dischargeable current] / [Battery rated capacity] × 100%
High Voltage Battery Heater System
If the temperature is too low, the battery can be frozen and it can cause reduction in the output voltage. So to prevent this, the heater system
for high voltage battery is adopted. It is controlled automatically by the temperature.
The heater relay is controlled by the BMS ECU and when the heater relay is ON, high voltage is supplied to each heater.
Even when the ignition switch is OFF, the VCU operates the BMS ECU regularly to prevent freezing of the battery.
If the temperature reaches normal range, BMS ECU waits until the VCU gives the order to operate the battery heater via CAN communication.
If the battery SOC is too low while the heater is operating, the BMS ECU stops the heater operation.
If the battery SOC is too low, the heater system will not operate even when the temperature is low.
Operation
High Voltage Battery Control System
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1.Measure the cell voltage, temperature, current and resistance value.
2.Transfer the BMS control data to VCU or control the driving part.
High Voltage Battery Heater System
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EV Battery System
Circuit Diagram
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High Voltage Circuit Diagram
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EV Battery System
Inspection
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
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Insulation Resistance Loss Inspection
1. Shut off the high voltage.
(Refer to Battery Contorl System - "High Voltage Shut-off Procedure")
2. Remove the high votlage battery upper case.
(Refer to High Voltage Battery System - "Case")
3. Remove the high voltage power cable (A).
High voltage power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Measure the voltage between the high voltage power cable and the ground cable.
Specified value :Approx. 0 V
EV Battery System
Specification
Item
Specification
Remark
C-CAN terminating resistance (Ω)
Approx. 60
Combined resistance (BMS ECU↔Inverter)
C-CAN terminating resistnace (Ω)
Approx. 120
BMS ECU resistance
EV Battery System
System Circuit Diagram
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Connector Location
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BMS ECU Connector And Terminal Function
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BMS ECU Terminal Function
A Connector [B01-A] (35 Pin) - Voltage Measurement Connector
Pin no.
Description
Connected to
1
Battery Cell [Module 8/Cell 13] Voltage Input
Battery Cell [Module 8/Cell 13]
2
Battery Cell [Module 8/Cell 10] Voltage Input
Battery Cell [Module 8/Cell 10]
3
Battery Cell [Module 8/Cell 7] Voltage Input
Battery Cell [Module 8/Cell 7]
4
Battery Cell [Module 8/Cell 4] Voltage Input
Battery Cell [Module 8/Cell 4]
5
Battery Cell [Module 7/Cell 4] Voltage Input
Battery Cell [Module 7/Cell 4]
6
7
Battery Cell [Module 7/Cell 1] Voltage Input
Battery Cell [Module 6/Cell 8] Voltage Input
Battery Cell [Module 7/ Cell 1]
Battery Cell [Module 6/Cell 8]
8
9
Battery Cell [Module 6/Cell 5] Voltage Input
Battery Cell [Module 8/Cell 14] Voltage Input
Battery Cell [Module 6/ Cell 5]
Battery Cell [Module 8/Cell 14]
10
Battery Cell [Module 8/Cell 11] Voltage Input
Battery Cell [Module 8/Cell 11]
11
12
Battery Cell [Module 8/Cell 9] Voltage Input
Battery Cell [Module 8/Cell 7] Voltage Input
Battery Cell [Module 8/Cell 9]
Battery Cell [Module 8/Cell 7]
13
Battery Cell [Module 8/Cell 5] Voltage Input
Battery Cell [Module 8/Cell 5]
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14
Battery Cell [Module 8/Cell 2] Voltage Input
Battery Cell [Module 8/Cell 2]
15
Battery Cell [Module 8/the Lower Line Cell] Voltage Input
Battery Cell [Module 8]
16
17
Battery Cell [Module 7/Cell 10] Voltage Input
Battery Cell [Module 7/Cell 8] Voltage Input
Battery Cell [Module 7/Cell 10]
Battery Cell [Module 7/Cell 8]
18
Battery Cell [Module 7/Cell 6] Voltage Input
Battery Cell [Module 7/Cell 6]
19
Battery Cell [Module 7/Cell 5] Voltage Input
Battery Cell [Module 7/Cell5]
20
Battery Cell [Module 7/Cell 2] Voltage Input
Battery Cell [Module 7/Cell 2]
21
Battery Cell [Module 7/the Lower Line Cell] Voltage Input
Battery Cell [Module 7]
22
Battery Cell [Module 6/Cell 9] Voltage Input
Battery Cell [Module 6/Cell 9]
23
Battery Cell [Module 6/Cell 6] Voltage Input
Battery Cell [Module 6/Cell 6]
24
-
25
Battery Cell [Module 8/Cell 12] Voltage Input
Battery Cell [Module 8/Cell 12]
26
27
Battery Cell [Module 8/Cell 8] Voltage Input
Battery Cell [Module 8/Cell 6] Voltage Input
Battery Cell [Module 8/Cell 8]
Battery Cell [Module 8/Cell6]
28
Battery Cell [Module 8/Cell 3] Voltage Input
Battery Cell [Module 8/Cell 3]
29
30
Battery Cell [Module 8/Cell 1] Voltage Input
Battery Cell [Module 7/Cell 9] Voltage Input
Battery Cell [Module 8/Cell1]
Battery Cell [Module 7/Cell 9]
31
32
Battery Cell [Module 7/Cell 7] Voltage Input
Battery Cell [Module 7/Cell 5] Voltage Input
Battery Cell [Module 7/Cell 7]
Battery Cell [Module 7]
33
Battery Cell [Module 7/Cell 3] Voltage Input
Battery Cell [Module 7/Cell 3]
34
Battery Cell [Module 6/Cell 10] Voltage Input
Battery Cell [Module 6/Cell 10]
35
Battery Cell [Module 6/Cell 7] Voltage Input
Battery Cell [Module 6/Cell 7]
B Connector [B01-B] (26 Pin) - Voltage Measurement Connector
Pin no.
Description
Connected to
1
Battery Cell [Module 6/Cell 3] Voltage Input
Battery Cell [Module 6/Cell 3]
2
3
Battery Cell [Module 6/Cell the Lower Line] Voltage Input
-
Battery Cell [Module 6]
4
5
Battery Cell [Module 5/Cell 6] Voltage Input
Battery Cell [Module 5/Cell 3] Voltage Input
Battery Cell [Module 5/Cell 6]
Battery Cell [Module 5/Cell 3]
6
Battery Cell [Module 5/Cell the Lower Line] Voltage Input
Battery Cell [Module 5]
7
8
Battery Cell [Module 6/Cell 4] Voltage Input
Battery Cell [Module 6/Cell 1] Voltage Input
Battery Cell [Module 6/Cell 4]
Battery Cell [Module 6/Cell 1]
9
-
10
11
Battery Cell [Module 5/Cell 13] Voltage Input
Battery Cell [Module 5/Cell 11] Voltage Input
Battery Cell [Module 5/Cell 13]
Battery Cell [Module 5/Cell 11]
12
13
Battery Cell [Module 5/Cell 9] Voltage Input
Battery Cell [Module 5/Cell 7] Voltage Input
Battery Cell [Module 5/Cell 9]
Battery Cell [Module 5/ Cell 7]
14
-
15
16
Battery Cell [Module 5/Cell 7] Voltage Input
Battery Cell [Module 5/Cell 4] Voltage Input
Battery Cell [Module 5/Cell 7]
Battery Cell [Module 5/Cell 4]
17
18
Battery Cell [Module 5/Cell 1] Voltage Input
Battery Cell [Module 6/Cell 5] Voltage Input
Battery Cell [Module 5/Cell 1]
Battery Cell [Module 6/Cell 5]
19
Battery Cell [Module 6/Cell 2] Voltage Input
Battery Cell [Module 6/Cell 2]
20
Battery Cell [Module 5/Cell 14] Voltage Input
Battery Cell [Module 5/Cell 14]
21
Battery Cell [Module 5/Cell 12] Voltage Input
Battery Cell [Module 5/Cell 12]
22
Battery Cell [Module 5/Cell 10] Voltage Input
Battery Cell [Module 5/Cell 10]
23
Battery Cell [Module 10/Cell 1] Voltage Input
Battery Cell [Module 10/Cell 1]
24
-
25
Battery Cell [Module 5/Cell 5] Voltage Input
Battery Cell [Module 5/Cell 5]
26
Battery Cell [Module 5/Cell 2] Voltage Input
Battery Cell [Module 5/Cell 2]
C Connector [B01-C] (28 Pin) - Voltage Measurement Connector
Pin no.
Description
Connected to
1
Battery Cell [Module 4/Cell 12] Voltage Input
Battery Cell [Module 4/Cell 12]
2
Battery Cell [Module 4/Cell 9] Voltage Input
Battery Cell [Module 4/Cell 9]
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3
Battery Cell [Module 4/Cell 7] Voltage Input
Battery Cell [Module 4/Cell 7]
4
Battery Cell [Module 4/Cell 5] Voltage Input
Battery Cell [Module 4/Cell 5]
5
6
Battery Cell [Module 3/Cell 5] Voltage Input
Battery Cell [Module 3/Cell 3] Voltage Input
Battery Cell [Module 3/Cell 5]
Battery Cell [Module 3/Cell 3]
7
Battery Cell [Module 3/Cell the Lower Line] Voltage Input
Battery Cell [Module 3]
8
Battery Cell [Module 4/Cell 13] Voltage Input
Battery Cell [Module 4/Cell 13]
9
Battery Cell [Module 4/Cell 10] Voltage Input
Battery Cell [Module 4/Cell 10]
10
Battery Cell [Module 4/Cell 8] Voltage Input
Battery Cell [Module 4/Cell 8]
11
Battery Cell [Module 4/Cell 6] Voltage Input
Battery Cell [Module 4/Cell 6]
12
Battery Cell [Module 4/Cell 3] Voltage Input
Battery Cell [Module 4/Cell 3]
13
Battery Cell [Module 4/Cell 1] Voltage Input
Battery Cell [Module 4/Cell 1]
14
Battery Cell [Module 4/ the Lower Line Cell] Voltage Input
Battery Cell [Module 4]
15
16
Battery Cell [Module 3/Cell 9] Voltage Input
Battery Cell [Module 3/Cell 7] Voltage Input
Battery Cell [Module 3/Cell 9]
Battery Cell [Module 3/Cell 7]
17
Battery Cell [Module 3/Cell 6] Voltage Input
Battery Cell [Module 3/Cell 6]
18
19
Battery Cell [Module 3/Cell 4] Voltage Input
Battery Cell [Module 3/Cell 1] Voltage Input
Battery Cell [Module 3/Cell4]
Battery Cell [Module 3/Cell1]
20
21
Battery Cell [Module 4/Cell 14] Voltage Input
Battery Cell [Module 4/Cell 11] Voltage Input
Battery Cell [Module 4/Cell 14]
Battery Cell [Module 4/Cell 11]
22
Battery Cell [Module 4/Cell 7] Voltage Input
Battery Cell [Module 4/Cell 7]
23
Battery Cell [Module 4/Cell 4] Voltage Input
Battery Cell [Module 4/Cell 4]
24
Battery Cell [Module 4/Cell 2] Voltage Input
Battery Cell [Module 4/Cell 2]
25
Battery Cell [Module 3/Cell 10] Voltage Input
Battery Cell [Module 3/Cell 10]
26
27
Battery Cell [Module 3/Cell 8] Voltage Input
Battery Cell [Module 3/Cell 5] Voltage Input
Battery Cell [Module 3/Cell 8]
Battery Cell [Module 3/Cell 5]
28
Battery Cell [Module 3/Cell 2] Voltage Input
Battery Cell [Module 3/Cell 2]
D Connector [B01-D] (30 Pin) - Voltage Measurement Connector
Pin no.
Description
1
Battery Cell [Module 2/Cell 8] Voltage Input
Connected to
Battery Cell [Module 2/Cell 8]
2
Battery Cell [Module 2/Cell 5] Voltage Input
Battery Cell [Module 2/Cell 5]
3
4
Battery Cell [Module 2/Cell 3] Voltage Input
Battery Cell [Module 2/ the Lower Line Cell] Voltage Input
Battery Cell [Module 2/Cell 3]
Battery Cell [Module 2]
5
Battery Cell [Module 1/Cell 5] Voltage Input
Battery Cell [Module 1/Cell 5]
6
7
Battery Cell [Module 1/Cell 2] Voltage Input
-
Battery Cell [Module 1/Cell 2]
8
9
Battery Cell [Module 2/Cell 9] Voltage Input
Battery Cell [Module 2/Cell 6] Voltage Input
Battery Cell [Module 2/Cell 9]
Battery Cell [Module 2/Cell 6]
10
Battery Cell [Module 2/Cell 5] Voltage Input
Battery Cell [Module 2/Cell 5]
11
12
Battery Cell [Module 2/Cell 4] Voltage Input
Battery Cell [Module 2/Cell 1] Voltage Input
Battery Cell [Module 2/Cell 4]
Battery Cell [Module 2/Cell 1]
13
Battery Cell [Module 1/Cell 13] Voltage Input
Battery Cell [Module 1/Cell 13]
14
Battery Cell [Module 1/Cell 12] Voltage Input
Battery Cell [Module 1/Cell 12]
15
Battery Cell [Module 1/Cell 10] Voltage Input
Battery Cell [Module 1/Cell 10]
16
Battery Cell [Module 1/Cell 8] Voltage Input
Battery Cell [Module 1/Cell 8]
17
Battery Cell [Module 1/Cell 7] Voltage Input
Battery Cell [Module 1/Cell 7]
18
Battery Cell [Module 1/Cell 6] Voltage Input
Battery Cell [Module 1/Cell 6]
19
Battery Cell [Module 1/Cell 3] Voltage Input
Battery Cell [Module 1/Cell 3]
20
Battery Cell [Module 1/Cell the Lower Line] Voltage Input
Battery Cell [Module 1]
21
22
Battery Cell [Module 2/Cell 10] Voltage Input
Battery Cell [Module 2/Cell 7] Voltage Input
Battery Cell [Module 2/Cell 10]
Battery Cell [Module 2/Cell 7]
23
-
24
Battery Cell [Module 2/Cell 2] Voltage Input
Battery Cell [Module 2/Cell 2]
25
Battery Cell [Module 1/Cell 14] Voltage Input
Battery Cell [Module 1/Cell 14]
26
Battery Cell [Module 1/Cell 11] Voltage Input
Battery Cell [Module 1/Cell 11]
27
Battery Cell [Module 1/Cell 9] Voltage Input
Battery Cell [Module 1/Cell 9]
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28
Battery Cell [Module 1/Cell 7] Voltage Input
Battery Cell [Module 1/Cell 7]
29
Battery Cell [Module 1/Cell 4] Voltage Input
Battery Cell [Module 1/Cell 4]
30
Battery Cell [Module 1/Cell 1] Voltage Input
Battery Cell [Module 1/Cell 1]
E Connector [B01-E] (26 Pin) - Control Connector
Pin no.
Description
1
Quick Charge Main Relay [+] Control
Connected to
High Voltage Joint Box
2
High Voltage Main Relay [-] Control
Power Relay Assembly (PRA)
3
High Voltage Main Relay [+] Control
Power Relay Assembly (PRA)
4
Pre Charge Relay Control
Power Relay Assembly (PRA)
5
6
High Voltage Cooling Fan Relay Control (FCTC)
Cooling Pan Speed Control
High Voltage Cooling Fan Relay Control
High Voltage Battery Cooling Pan
7
Cooling Pan Feedback Input Signal
High Voltage Battery Cooling Pan
8
9
Quick Charge SS2 Input Signal
Quick Charge Port
10
Quick Charge PD Input Signal
Quick Charge Port
11
High Voltage Joint Box Interlock Input Signal
High Voltage Joint Box
-
12
Battery Current Sensor Input Signal
Power Relay Assembly (PRA)
13
Battery Current Sensor Power (+5V)
Power Relay Assembly (PRA)
14
Quick Charge Main Relay (-) Control
High Voltage Joint Box
15
16
Quick Charge Main Relay Ground
High Voltage Main Relay Ground
High Voltage Joint Box
Power Relay Assembly (PRA)
17
High Voltage Battery Heater Relay Control
Power Relay Assembly (PRA)
18
19
-
20
-
21
22
Collision Test Input Signal (Crash)
-
23
24
-
25
26
Collision detection signal
Battery Current Sensor Ground
Power Relay Assembly (PRA)
F Connector [B01-F] (16 Pin) - Temperature Measurement Connector
Pin no.
Description
1
Battery Temperature Sensor #4 [Module4] Signal Input
Connected to
Battery Temperature Sensor #4
2
3
Battery Temperature Sensor #3 [Module3] Signal Input
Battery Temperature Sensor #2 [Module2] Signal Input
Battery Temperature Sensor #3
Battery Temperature Sensor #2
4
Battery Temperature Sensor #1 [Module1] Signal Input
Battery Temperature Sensor #1
5
6
High Voltage Battery Heater Temperature Sensor #1
7
High Voltage Battery Heater Temperature Sensor #1 [Module1]
Signal Input
-
8
Safety Plug Interlock Signal Input
Interlock (Included in the Safety Plug)
9
Battery Temperature Sensor #4 [Module4] Ground
Battery Temperature Sensor #4
10
Battery Temperature Sensor #3 [Module3] Ground
Battery Temperature Sensor #3
11
Battery Temperature Sensor #2 [Module2] Ground
Battery Temperature Sensor #2
12
Battery Temperature Sensor #1 [Module1] Ground
Battery Temperature Sensor #1
13
14
High Voltage Battery Heater Temperature Sensor #1 [Module1]
Ground
15
16
HighVoltage Battery Heater Temperature Sensor #1
Safety Plug Interlock Ground
Interlock (Included in the Safety Plug)
G Connector [B01-G] (12 Pin) - Temperature Measurement Connector
Pin no.
1
Description
Battery Temperature Sensor #8 [Module 8] Signal Input
Connected to
Battery Temperature Sensor #8
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2
Battery Temperature Sensor #7 [Module 7] Signal Input
Battery Temperature Sensor #7
3
Battery Temperature Sensor #6 [Module 6] Signal Input
Battery Temperature Sensor #6
4
5
Battery Temperature Sensor #5 [Module 8] Signal Input
Inlet Temperature Sensor Signal Input
Battery Temperature Sensor #5
Inlet Temperature Sensor
6
High Voltage Battery Heater Temperature Sensor #2 [Module2]
Signal Input
HighVoltage Battery Heater Temperature Sensor #2
7
Battery Temperature Sensor #8 [Module 8] Ground
Battery Temperature Sensor #8
8
Battery Temperature Sensor #7 [Module 7] Ground
Battery Temperature Sensor #7
9
Battery Temperature Sensor #6 [Module 6] Ground
Battery Temperature Sensor #6
10
Battery Temperature Sensor #5 [Module 8] Ground
Battery Temperature Sensor #5
11
Inlet Temperature Sensor Ground
Inlet Temperature Sensor
12
High Voltage Battery Heater Temperature Sensor #2 [Module2]
Ground
High Voltage Battery Heater Temperature Sensor #2
H Connector [B01-H] (22 Pin) - Control Connector
Pin no.
1
2
3
4
5
Description
Connected to
Inverter Interlock Signal Input
Power Relay Assembly (PRA)
C-CAN [Low]
Other Control Module, Data Link Connector (DLC), Multi-Check
Connector
C-CAN [High]
Other Control Module, Data Link Connector (DLC), Multi-Purpose
Check Connector
Other Control Module, Data Link Connector (DLC), Multi-Purpose
Check Connector
Other Control Module, Data Link Connector (DLC), Multi-Purpose
Check Connector
CCP-CAN [Low]
CCP-CAN [High]
6
-
7
Runaway Arresting Device (RAD) Signal Input
Runaway Arresting Device (RAD)
8
9
Normal charging device ON (Wake up) Signal Input
IG3 Power
Normal charging device, IG3 #2 Relay
12V Auxiliary Battery
10
Battery Power (B+)
12V Auxiliary Battery, IG3 #1/2/3 Relay
11
Battery Power (B+)
12V Auxiliary Battery, IG3 #1/2/3 Relay
12
-
13
14
-
15
16
-
17
18
19
Quick Charge Port Signal Input (Pilot)
-
20
21
22
Quick Charge Port
Power Ground
Power Ground
Chassis Ground
Chassis Ground
BMS ECU Terminal Input/Output Signal
A Connector [B01-A] (35 Pin) - Voltage Measurement Connector
Pin
no.
Description
Condition
Type
Level
Wave
Remark
1
Battery Cell [Module 8/Cell 13]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.13 Cell
2
Battery Cell [Module 8/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.10 Cell
3
Battery Cell [Module 8/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.7 Cell
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.4 Cell
4
Battery Cell [Module 8/Cell 4]
Voltage Input
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5
Battery Cell [Module 7/Cell 4]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.4 Cell
6
Battery Cell [Module 7/Cell 1]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.1 Cell
7
Battery Cell [Module 6/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.8 Cell
8
Battery Cell [Module 6/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.5 Cell
9
Battery Cell [Module 8/Cell 14]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.14 Cell
10
Battery Cell [Module 8/Cell 11]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.11 Cell
11
Battery Cell [Module 8/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.9 Cell
12
Battery Cell [Module 8/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.7 Cell
13
Battery Cell [Module 8/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.5 Cell
14
Battery Cell [Module 8/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.2 Cell
15
Battery Cell [Module 8/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module The Lower
Line
16
Battery Cell [Module 7/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.10 Cell
17
Battery Cell [Module 7/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.8 Cell
18
Battery Cell [Module 7/Cell 6]
Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.6 Cell
19
Battery Cell [Module 7/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.5 Cell
20
Battery Cell [Module 7/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.2 Cell
21
Battery Cell [Module 7/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module The Lower
Line
22
Battery Cell [Module 6/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.9 Cell
23
Battery Cell [Module 6/Cell 6]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.6 Cell
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24
-
25
Battery Cell [Module 8/Cell 12]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.12 Cell
26
Battery Cell [Module 8/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.8 Cell
27
Battery Cell [Module 8/Cell 6]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.6 Cell
28
Battery Cell [Module 8/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.3 Cell
29
Battery Cell [Module 8/Cell 1]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.8 Module No.1 Cell
30
Battery Cell [Module 7/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.9 Cell
31
Battery Cell [Module 7/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.7 Cell
32
Battery Cell [Module 7/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.5 Cell
33
Battery Cell [Module 7/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.7 Module No.3 Cell
34
Battery Cell [Module 6/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.10 Cell
35
Battery Cell [Module 6/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.7 Cell
B Connector [B01-B] (26 Pin) - Voltage Measurement Connector
Pin
no.
Description
Condition
Type
Level
Wave
Remark
1
Battery Cell [Module 6/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.3 Cell
2
Battery Cell [Module 6/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module The Lower
Line
3
-
4
Battery Cell [Module 5/Cell 6]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.6 Cell
5
Battery Cell [Module 5/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.3 Cell
6
Battery Cell [Module 5/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module The Lower
Line
7
Battery Cell [Module 6/Cell 4]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.4 Cell
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.1 Cell
8
Battery Cell [Module 6/Cell 1]
Voltage Input
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9
-
10
Battery Cell [Module 5/Cell 13]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.13 Cell
11
Battery Cell [Module 5/Cell 11]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.11 Cell
12
Battery Cell [Module 5/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.9 Cell
13
Battery Cell [Module 5/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.7 Cell
14
-
15
Battery Cell [Module 5/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.7 Cell
16
Battery Cell [Module 5/Cell 4]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.4 Cell
17
Battery Cell [Module 5/Cell 1]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.1 Cell
18
Battery Cell [Module 6/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.5 Cell
19
Battery Cell [Module 6/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.6 Module No.2 Cell
20
Battery Cell [Module 5/Cell 14]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.14 Cell
21
Battery Cell [Module 5/Cell 12]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.12 Cell
22
Battery Cell [Module 5/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.10 Cell
23
Battery Cell [Module 5/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.8 Cell
24
-
25
Battery Cell [Module 5/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.5 Cell
26
Battery Cell [Module 5/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.5 Module No.2 Cell
C Connector [B01-C] (28 Pin) - Voltage Measurement Connector
Pin
no.
Description
Condition
Type
Level
Wave
Remark
1
Battery Cell [Module 4/Cell 12]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.12 Cell
2
Battery Cell [Module 4/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.9 Cell
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.7 Cell
3
Battery Cell [Module 4/Cell 7]
Voltage Input
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4
Battery Cell [Module 4/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.5 Cell
5
Battery Cell [Module 3/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.5 Cell
6
Battery Cell [Module 3/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.3 Cell
7
Battery Cell [Module 3/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module The Lower
Line
8
Battery Cell [Module 4/Cell 13]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.13 Cell
9
Battery Cell [Module 4/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.10 Cell
10
Battery Cell [Module 4/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.8 Cell
11
Battery Cell [Module 4/Cell 6]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.6 Cell
12
Battery Cell [Module 4/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.3 Cell
13
Battery Cell [Module 4/Cell 1]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.1 Cell
14
Battery Cell [Module 4/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module Cell The
Lower Line
15
Battery Cell [Module 3/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.9 Cell
16
Battery Cell [Module 3/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.7 Cell
17
Battery Cell [Module 3/Cell 6]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.6 Cell
18
Battery Cell [Module 3/Cell 4]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.4 Cell
19
Battery Cell [Module 3/Cell 1]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.1 Cell
20
Battery Cell [Module 4/Cell 14]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.14 Cell
21
Battery Cell [Module 4/Cell 11]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.11 Cell
22
Battery Cell [Module 4/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.7 Cell
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23
Battery Cell [Module 4/Cell 4]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.4 Cell
24
Battery Cell [Module 4/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.4 Module No.2 Cell
25
Battery Cell [Module 3/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.10 Cell
26
Battery Cell [Module 3/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.8 Cell
27
Battery Cell [Module 3/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.5 Cell
28
Battery Cell [Module 3/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.3 Module No.2 Cell
D Connector [B01-D] (30 Pin) - Voltage Measurement Connector
Pin
no.
Description
Condition
Type
Level
Wave
Remark
1
Battery Cell [Module 2/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
2 Module No.8 Cell
2
Battery Cell [Module 2/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.5 Cell
3
Battery Cell [Module 2/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.3 Cell
4
Battery Cell [Module 2/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module The Lower
Line
5
Battery Cell [Module 1/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.5 Cell
6
Battery Cell [Module 1/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.2 Cell
7
-
8
Battery Cell [Module 2/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.9 Cell
9
Battery Cell [Module 2/Cell 6]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.6 Cell
10
Battery Cell [Module 2/Cell 5]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.5 Cell
11
Battery Cell [Module 2/Cell 4]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.4 Cell
12
Battery Cell [Module 2/Cell 1]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.1 Cell
13
Battery Cell [Module 1/Cell 13]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.13 Cell
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.12 Cell
14
Page 130 sur 245
Battery Cell [Module 1/Cell 12]
Voltage Input
15
Battery Cell [Module 1/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.10 Cell
16
Battery Cell [Module 1/Cell 8]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.8 Cell
17
Battery Cell [Module 1/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.7 Cell
18
Battery Cell [Module 1/Cell 6]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.6 Cell
19
Battery Cell [Module 1/Cell 3]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.3 Cell
20
Battery Cell [Module 1/Cell The
Lower Line] Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module The Lower
Line
21
Battery Cell [Module 2/Cell 10]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.10 Cell
22
Battery Cell [Module 2/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.7 Cell
23
-
24
Battery Cell [Module 2/Cell 2]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.2 Module No.2 Cell
25
Battery Cell [Module 1/Cell 14]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.14 Cell
26
Battery Cell [Module 1/Cell 11]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.11 Cell
27
Battery Cell [Module 1/Cell 9]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.9 Cell
28
Battery Cell [Module 1/Cell 7]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.7 Cell
29
Battery Cell [Module 1/Cell 4]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.4 Cell
30
Battery Cell [Module 1/Cell 1]
Voltage Input
IG Off
DC Voltage
1.5 ~ 4.8V
No.1 Module No.1 Cell
E Connector [B01-E] (26 Pin) - Control Connector
Pin
no.
Description
Condition
Type
Level
1
On : VB ± 1.0V
Quick Charge Main Relay [+] QuickCharger
DC
Control
Connect
Voltage Off : Max 1.0V
2
High Voltage Main Relay [-]
Control
3
Starting
Starting
On : VB ± 1.0V
DC
Voltage Off : Max1.0V
Wave
Remark
Quick Charger Main
Relay Control Signal
(Active High)
Main Relay Control
Signal (Active High)
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High Voltage Main Relay [+]
Control
4 Pre Charge Relay Control
5
High Voltage Battery Cooling
Fan Relay Control (FCTL)
DC
On : VB ± 1.0V
Voltage Off : Max1.0V
Main Relay Control
Signal (Active High)
Starting
On : VB ± 1.0V
DC
Voltage Off : Max1.0V
Pre Charge Relay
Control Signal (Active
High)
IG On
On : Max1.0V
DC
Voltage Off : VB ± 0.5V
Cooling Relay Control
Signal (Active Low)
Cooling Pan Speed Control
6
Starting
Pulse
0 ~ 5.0V
Cooling fan motor
Speed Control Signal
(PWM duty)
Pulse
0 ~ 5.0V
Cooling fan Speed
Feedback Signal
(0 ~ 3000Hz)
7
Cooling Pan Feedback Signal
Input (VF1)
Starting
8
Quick Charge SS2 Signal
Input
Quick
Charger
Connect
DC
On : 12 ± 1.0V Off :
Voltage 0.9 V Max
Quick Charger and
BMS Interface (SAE
J1772)
Quick
Charger
Connect
DC
On : 0.9V Max Off :
Voltage
5.0 ± 0.1V Max
QuickCharger and
BMS Interface (SAE
J1772)
9
-
10 Quick Charge PD Signal Input
Joint Box in
HighVoltage Connector
Interlock (Active Low)
IG On
DC
Voltage
Battery Current Sensor Signal
12
Input
IG On
DC
Voltage
Battery Current Sensor Power
(+5V)
IG On
DC
Voltage
Quick Charge Main Relay (-)
14
Control
Quick
Charger
Connect
DC
Voltage
On :
VB ± 0.5V
Off :
1.0V Max
Quick Charge Main
Relay Control Signal
(Active High)
15
Quick Charge Main Relay
Ground
Quick
Charger
Connect
DC
Voltage
Max.150mV @
12V assistance
Battery Ground
Quick Charge Relay
Ground
16
HighVoltage Main Relay
Ground
IG On
DC
Voltage
Max.150mV @
12V assistance
Battery Ground
Quick Charge Relay
Ground
17
HighVoltage Battery Heater
Relay Control
High voltage
battery
DC
Voltage
heater
system action
On : VB ± 1.0V
Off : Max 1.0V
High Voltage Battery
Heater Relay Control
Signal (Active High)
11
13
High Voltage Joint Box
Interlock Signal Input
Safety Plug
Installation : 0.9V
Max
Safety Plug
Removal : 5.0 ±
0.1V
18
19
-
20
-
21 Collision Test Input(Crash)
IG On
Pulse
0A :
2.4 ~ 2.6 V
-300~300A :
0.4~4.6V
On :
4.9 ~ 5.1 V
Off :
Max1.0V
0 ~ 5.0V
Current Sensor
(Current sensing value)
Current Sensor (Input
Power (5V))
Collision detection
signall (PWM Duty)
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22
-
23
24
-
25
-
26
Battery Current Sensor
Ground
IG On
DC
Voltage
Max.150mV @
12V assistance
Battery Ground
Battery Current Sensor
Ground
F Connector [B01-F] (16 Pin) - Temperature Measurement Connector
Pin
no.
Description
Condition
Type
Level
1
Battery Temperature Sensor #4
[Module4] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (No.4 Module)
2
Battery Temperature Sensor #3
[Module3] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (No.3 Module)
3
Battery Temperature Sensor #2
[Module2] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (2번 Module)
4
Battery Temperature Sensor #1
[Module1] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (No.1 Module)
IG On
DC Voltage
0.3 ~ 4.9V
High Voltage Battery
Heater Temperature
Sensor (No.1 Module)
Safety Plug Interlock
(Active Low)
5
6
7
Wave
Remark
High Voltage Battery Heater
Temperature Sensor #1
[Module1] Signal Input
-
8
Safety Plug Interlock Signal
Input
IG On
Safety Plug
Installation : Max
0.1V
DC Voltage
Safety Plug
Removal : 4.9 ~ 5.1V
9
Battery Temperature Sensor #4
[Module4] Ground
IG On
DC Voltage
0.1V Max
Battery Temperature
Sensor (No.4 Module)
10
Battery Temperature Sensor #3
[Module3] Ground
IG On
DC Voltage
0.1V Max
Battery Temperature
Sensor (No.3 Module)
11
Battery Temperature Sensor #2
[Module2] Ground
IG On
DC Voltage
0.1V Max
Battery Temperature
Sensor (No.2 Module)
12
Battery Temperature Sensor #1
[Module1] Ground
IG On
DC Voltage
0.1V Max
Battery Temperature
Sensor (No.1 Module)
13
IG On
DC Voltage
0.1V Max
High Voltage Battery
Heater Temperature
Sensor (No.1 Module)
IG On
DC Voltage
0.1V Max
Safety Plug Interlock
14
15
16
High Voltage Battery Heater
Temperature Sensor #1
[Module1] Ground
Safety Plug Interlock Ground
G Connector [B01-G] (12 Pin) - Temperature Measurement Connector
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Pin
no.
Description
Condition
Type
Level
1
Battery Temperature Sensor #8
[Module8] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (No.8 Module)
2
Battery Temperature Sensor #7
[Module7] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (No.7 Module)
3
Battery Temperature Sensor #6
[Module6] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (No.6 Module)
4
Battery Temperature Sensor #5
[Module8] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
Battery Temperature
Sensor (No.5 Module)
5
Inlet Temperature Sensor Signal
Input
IG On
DC Voltage
0.3 ~ 4.9V
Inlet Temperature Sensor
6
High Voltage Battery Heater
Temperature Sensor #2
[Module2] Signal Input
IG On
DC Voltage
0.3 ~ 4.9V
HighVoltage Battery
Heater Temperature
Sensor (No.8 Module)
7
Battery Temperature Sensor #8
[Module8] Ground
IG On
DC Voltage
0.1V Max
BatteryTemperatureSensor
Ground
8
Battery Temperature Sensor #7
[Module7] Ground
IG On
DC Voltage
0.1V Max
BatteryTemperatureSensor
Ground
9
Battery Temperature Sensor #6
[Module6] Ground
IG On
DC Voltage
0.1V Max
BatteryTemperatureSensor
Ground
10
Battery Temperature Sensor #5
[Module8] Ground
IG On
DC Voltage
0.1V Max
BatteryTemperatureSensor
Ground
11
Inlet Temperature Sensor
Ground
IG On
DC Voltage
0.1V Max
BatteryTemperatureSensor
Ground
12
High Voltage Battery Heater
Temperature Sensor #2
[Module2] Ground
IG On
DC Voltage
0.1V Max
HighVoltage Battery
Heater Temperature
Sensor Ground
Wave
Remark
H Connector [B01-H] (22 Pin) - Control Connector
Pin
no.
Description
1 Inverter Interlock Signal Input
Condition
IG On
Type
Level
Safety Plug
Installation: Max
0.9V
DC
Voltage Safety Plug
Removal: 4.9 ~ 5.1
V
2 C-CAN [Low]
IG On
Pulse
Receive :
2.0 ~3.0(2.5)V
Dominant :
0.5~2.25(1.5)V
3 C-CAN [High]
IG On
Pulse
Dominant :
2.75~4.5(3.5)V
Receive : 2.0~3.0
(2.5)V
4 CCP-CAN [Low]
IG On
Pulse
Wave
Remark
Safety Plug Interlock
(Active Low)
Vechicle CAN
Communication (Low)
Vechicle CAN
Communication (High)
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Receive :
2.0 ~3.0(2.5)V
Dominant :
0.5~2.25(1.5)V
5 CCP-CAN [High]
6
IG On
Pulse
Dominant :
2.75~4.5(3.5)V
Receive : 2.0~3.0
(2.5)V
Quick Charge CAN
Communication (Low)
Quick Charge CAN
Communication (High)
-
Runaway Arresting Device
7
(RAD) Signal Input
IG On
Quick
Quick Charger ON (Wake up)
Charger
Signal Input
connection
8
No Operation:
Max1.0V
DC
Voltage Operation:
VB ± 1.0V
Relay operation
Feedback Signal
(Active High)
DC
On : 12 ± 1.0V Off :
Voltage 0.9 V Max
Quick Charger
from BMS ECU wakeup Signal
9 IG3 Power
IG On
DC
9 < VIG1 < 16V
Voltage
IG3 Signal
10 Battery Power (B+)
Always
DC
9 < VB < 16V
Voltage
BMS ECU
Power
11 Battery Power (B+)
Always
DC
9 < VB < 16V
Voltage
BMS ECU
Power
Quick
Charger
connection
0 ~ 12V
DC
Voltage Connect quick
Charger 9V or 0V)
Quick Charger and
BMS ECU interface
(SAE J1772)
IG On
Safety Plug
Installation: 0.9V
Max
DC
Voltage Safety Plug
Removal:4.9 ~ 5.1
V
Safety Plug Interlock
(Active Low)
21 PowerGround
Always
DC
Max.150mV @12V
Voltage Battery Ground
Ground
22 PowerGround
Always
DC
Max.150mV @12V
Voltage Battery Ground
Ground
12
13
-
14
-
15
16
-
17
-
18
Rapid Charge Port signal
input (Pilot)
19 Inverter Interlock Signal Input
20
-
EV Battery System
Inspection
C-CAN Terminating Resistance Inspection (Multi Purpose Check Connector)
1. Turn the ignition OFF.
2. Measure the resistance between pins No. 20 and No. 17 of multi purpose check connector (20 pins).
Measure the resistance between pins No. 3 and No. 11 of DLC (16 pins).
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Specified value :Approx. 60 Ω
3. If the measured vaule is not whithin the specification, check the terminating resistance between the BMS ECU and the Inverter.
C-CAN Terminating Resistance (BMS ECU)
1. Turn the ignition OFF and disconnect the auxiliary battery negative (-) terminal.
2. Lift the vehicle.
3. After loosening the mounting nut, remove the high voltage battery front under cover (A).
4. Disconnect the BMS ECU extension connector (A).
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5. Measure the resistance between pins No. 2 (CAN-High) and No. 9 (CAN-Low) of BMS ECU.
Specified value :Approx. 120 Ω
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Shut off the high voltage.
(Refer to EV Battery System - "High Voltage Shut-off Procedure")
2. Remove the high voltage battery pack assembly.
(High Voltage Battery System - Battery Pack Assembly - "Removal")
3. Remove the safety plug cable assembly bracket mounting bolt (A).
Safety plug cable assembly bracket mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. After loosening the mounting bolt, remove the upper case (A).
High voltage battery pack upper case mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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5. Remove the BMS ECU
(1) Disconnect the connector (A).
(2) Remove the mounting nut (B).
(3) Remove the BMS ECU(C).
BMS ECU mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Install the BMS ECU in the reverse order of removal.
EV Battery System
Specification
Item
ON
Coil
Specification
Rated Voltage (V)
450
Rated Ampere (A)
200
Voltage Drop (V)
Less than 0.1 (200A)
Operation Voltage (V)
12
Resistance (Ω)
21.6 ~ 26.4 (20°C)
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Item
Specification
Note
Main Relay Fixing Status
Main Relay Switch (-) Resistance (Ω)
NO
∞
Checkable by GDS
Checkable by multi tester
Main Relay Operation Beep
"Clicking"
Checkable by GDS and SST
Coil Resistance (Ω)
21.6 ~ 26.4 (20°C)
Checkable by multi tester
EV Battery System
Description
Main Relay is installed in the Power Relay Assembly (PRA) and it controls the high voltage line.
It connects the power between the high voltage battery pack and the high voltage joint box by the BMS ECU control signal.
But when the battery cell is swollen by overcharging, main relay and pre charge relay (PRA) are not operated by RAD.
The RAD is installed on each battery module and will not operate when the battery is normal.
[With High Voltage Battey Heater System]
1. Main Relay (+)
2. Main Relay (-)
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3. Pre Charge Relay
4. Pre Charge Resistor
5. Battery Current Sensor
6. High Voltage Battery Heater Relay
7. High Voltage Battery Heater Fuse
[Without High Voltage Battery Heater System]
1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
Operation
4. Pre Charge Resistor
5. Battery Current Sensor
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EV Battery System
System Circuit Diagram
With High Voltage Battery Heater System
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Without High Voltage Battery Heater System
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Circuit Diagram
Without High Voltage Battery Heater System
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With High Voltage Battery Heater System
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EV Battery System
Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
Main Relay (-) Inscpection
[Using multi tester (Relay OFF)]
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Inspect the high voltage main relay (-) by using multi tester when the relay is off
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
3. Measure the resistance between the high voltage (-) power terminal and the Inverter (-) terminal.
Specification :∞Ω(20°C)
[Using GDS (Relay ON)]
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
3. Connect the SST No: 0K918-E4100, 0K375-E4100, 0K375-E4200 to the vehicle.
4. Connect the GDS to DLC.
5. Turn the ignition switch ON.
6. Activate the main relay (-) by using "Actuation Test" on the GDS as shown in the illustration below.
When the relay is ON, there is a relay operation sound.
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Main Relay Coil Resistance
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")
3. Measure the resistance of the main relay (+) (between the No.6 and the No.10) and the main relay (-) (between the No.4 and the No.6).
Specification :21.6 ~ 26.4 Ω (20°C)
Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
Specification
Item
ON
Coil
Item
Specification
Rated Voltage(V)
450
Rated Ampere(A)
Voltage Drop(V)
10
Less than 0.5 (10A)
Operation Voltage(V)
12
Resistance(Ω)
104.4 ~ 127.6 (20°C)
Specification
Remark
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Main Relay Switch (-) Resistance (Ω)
∞
Checkable by multi tester
Pre Charger Relay Operation Sound
"Clicking"
Checkable by GDS and SST
Pre Charger Relay Coil Resistance (Ω)
104.4 ~ 127.6 (20°C)
Checkable by multi tester
EV Battery System
Description
Installed in the Power Relay Assembly (PRA), the Pre-charge Relay connects high voltage circuit when pre-charging the inverter capacitor.
When the IG is ON, the current coming through the pre-charge relay and the resistor charges the capacitor in the inverter and when the
capacitor is fully charged, the pre-charge relay turns OFF.
[With High Voltage Battery Heater System]
1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
4. Pre Charge Resistor
[Without High Voltage Battery Heater System]
5. Battery Current Sensor
6. High Voltage Battery Heater Relay
7. High Voltage Battery Heater Fuse
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1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
Operation
4. Pre Charge Resistor
5. Battery Current Sensor
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EV Battery System
System Circuit Diagram
With High Voltage Battery Heater System
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Without High Voltage Battery Heater System
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Circuit Diagram
Without High Voltage Battery Heater System
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With High Voltage Battery Heater System
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EV Battery System
Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
Pre Charge Relay Inspection
[Using multi tester (Relay OFF)]
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Inspect the high voltage pre-charge relay by using multi tester when the relay is off
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
3. Measure the resistance between the high voltage (+) power terminal and the joint box (+) terminal.
Specification :∞Ω(20°C)
[Using GDS (Relay ON)]
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
3. Connect the SST(0K918-E4100, 0K375-E4100, 0K375-E4200) to the vehicle.
4. Connect the GDS to DLC.
5. Turn the ignition swtich ON.
6. Activate the pre charge relay by using "Actuation Test" on the GDS as shown in the illustration below.
When the relay is ON, there is a relay operation sound.
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Pre Charge Relay Coil Resistance
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the power relay assembly (PRA)
(Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")
3. Measure the resistance between pins No. 6 and No. 8 of the power relay assembly connector.
Specification :104.4 ~ 127.6 Ω (20°C)
Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
Spectification
Item
Coil
Specification
Capacity (W)
Resistance (Ω)
60
30
EV Battery System
Description
Pre-Charge Resistor is installed in the Power Relay Assembly (PRA) and it protects the high voltage circuit by limiting the charging current
when the inverter capacitor is being pre-charged.
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[With High Voltage Battery Heater System]
1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
4. Pre Charge Resistor
[Without High Voltage Battery Heater System]
5. Battery Current Sensor
6. High Voltage Battery Heater Relay
7. High Voltage Battery Heater Fuse
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1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
Operation
4. Pre Charge Resistor
5. Battery Current Sensor
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EV Battery System
System Circuit Diagram
With High Votlage Battery Heater System
Page 159 sur 245
Without High Voltage Battery Heater System
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Circuit Diagram
Without High Voltage Battery Heater System
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With High Voltage Battery Heater System
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EV Battery System
Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
Page 163 sur 245
Specifications
Current (A)
-400(Charge)
Ouput Voltage (V)
0.5
-200 (Charge)
1.5
0
2.5
200 (Discharge)
3.5
+400 (Discharge)
4.5
Item
Specifications
Remark
Current Sensor Output Voltage (V)
Current Sensor Power Voltage (V)
Approx. 2.5 ± 0.1
Approx. 5 ± 0.1
Checkable by multi tester
Checkable by multi tester
EV Battery System
Description
Battery Current Sensor is installed in the Power Relay Assembly and it measures the current when the high voltage battery is being charged
or discharged.
[With High Voltage Battery Heater System]
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1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
4. Pre Charge Resistor
[Without High Voltage Battery Heater System]
5. Battery Current Sensor
6. High Voltage Battery Heater Relay
7. High Voltage Battery Heater Fuse
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1. Main Relay (+)
2. Main Relay (-)
3. Pre Charge Relay
EV Battery System
Systerm Circuit Diagram
With High Voltage Battery Heater System
4. Pre Charge Resistor
5. Battery Current Sensor
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Without High Voltage Battery Heater System
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Circuit Diagram
Without High Voltage Battery Heater System
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With High Voltage Battery Heater System
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EV Battery System
Inspection
1. Turn the ignition switch OFF.
2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Prcedure")
3. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repair procedures - "Removal")
4. Remove the high voltage battery pack upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) to the vehicle as shown in the image below.
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6. Connect the GDS to DLC.
7. Turn the ignition switch ON.
8. Check the "Battery Pack Current" in the GDS service data.
9. Check voltage for each current.
Current (A)
Output Voltage (V)
-400(Charge)
-200 (Charge)
0.5
1.5
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0
2.5
200 (Discharge)
3.5
+400 (Discharge)
4.5
10. Measure the voltage between pins No. 12 (Sensor output) and No. 26 (Sensor ground) of BMS ECU E connector.
Specification :About 2.5V ± 0.1V
11. Measure the voltage between pins No. 1 (Sensor power) and No. 26 (Sensor ground) of BMS ECU E connector.
Specification :Approx. 5V ± 0.1V
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Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
Description
Safety Plug is installed on the bottom of the rear seat. High voltage circuit can be shut off by removing the safety plug.
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EV Battery System
System Circuit Diagram
Circuit Diagram
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EV Battery System
Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Remove the safety plug. (Refer to "Removal")
2. Check the safety plug by visual check and electrical test.
- Check the interlock switch and terminal
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
[Safety Plug]
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1. Turn the ignition swtich OFF and disconnect the auxiliary battery negative (-) terminal.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :0.8 ~ 1.2 kgf.m
4. Remove the safety plug (A).
Remove the safety plug in the following order.
[Safety Plug Cable]
1. Turn the ignition switch OFF and disconnect the auxiliary batter negative (-) terminal.
2. Shut off the high voltage.
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(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3. Remove the high voltage upper case.
(Refer to High Voltage Battery System - "Case")
4. Disconnect the safety plug cable inerlock connector (A).
5. After loosening the nunt (A), remove the safety plug cable assembly (B).
Safety plug cable assembly mounting nut :0.8 ~ 1.2 kgf.m
Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Install the safety plug in the reverse order of removal.
EV Battery System
Specification
Item
Specification
Rated Voltage (V)
Rated Current (A)
450 (DC)
250 (DC)
Item
Specification
Remark
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Safety Plug Cable Resistance (Ω)
Less than 1 (20°C)
Checkable by multi tester
Main Fuse Resistance (Ω)
Less than 1 (20°C)
Checkable by multi tester
EV Battery System
Description
Installed in the safety plug, the main fuse protects the high voltage circuit from overcurrent.
EV Battery System
System Circuit Diagram
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Circuit Diagram
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EV Battery System
Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
Method 1
1. Remove the safety plug.
(Refer to High Voltage Battery Control System - "Safety Plug")
2. Measure the resistance of safety plug cable which is connected to main fuse.
Specification :Less than 1Ω (20°C)
Method 2
1. Turn the ignition switch OFF and disconnect the auxiliary battery negative (-) terminal.
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2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
4. Remove the upper fuse box (A).
5. Perform the electrical test of main fuse.
Specification :Less than 1Ω (20°C)
Removal
Main fuse is combined with the safety plug. Refer to the removal procedure of safety plug.
Installation
Main fuse is combined with the safety plug. Refer to the removal procedure of safety plug.
EV Battery System
Specification
Temperature (°C)
Resistance (KΩ)
Tolerance (%)
-40
204.5
±4.0
-30
117.8
±3.5
- 20
- 10
70.34
43.43
±3.0
±2.5
0
27.63
±2.0
10
20
18.07
12.11
±1.6
±1.2
30
8.303
±1.2
40
5.813
±1.5
50
4.149
±1.9
60
3.013
±2.2
70
2.225
±2.5
EV Battery System
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Description
Installed in the high voltage battery module, Battery Temperature Sensor transfers temperature of each battery module to BMS ECU.
EV Battery System
Circuit Diagram
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EV Battery System
Installation
Battery temperature sensor can not be disassembled.
1. Turn the ignition switch OFF.
2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repair procedures - "Removal")
4. Remove the high voltage battery pack upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) as shown in the image below.
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6. Connect the GDS to DLC.
7. Turn the ignition switch ON.
8. Check the "Battery Module Temperature" in the GDS service data.
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9. Turn the ignition swtich OFF.
10. Disconnect the SST (high votlage battery cable & BMS terminal).
11. Check resistance for each temperature sensor.
Temperature (°C)
-40
Resistance (KΩ)
204.5
Tolerance (%)
±4.0
-30
117.8
±3.5
- 20
- 10
70.34
43.43
±3.0
±2.5
0
10
27.63
18.07
±2.0
±1.6
20
12.11
±1.2
30
40
8.303
5.813
±1.2
±1.5
50
4.149
±1.9
60
70
3.013
2.225
±2.2
±2.5
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EV Battery System
Specification
Item
RAD Combined Resistance (Ω)
Specification
Less than 3 (20°C)
RAD Terminal Resistance (Ω)
Less than 0.375 (20°C)
Checkable by multi tester
RAD Switch Position
Bottom
RAD switch and visual inspection
EV Battery System
Components Location
Remark
Checkable by multi tester
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1. Runaway Arresting Device (RAD)
2. Runaway Arresting Device (RAD) Wiring Harness
EV Battery System
Description
RAD is installed on each battery module.
If the high voltage battery is swollen by cell overcharge, RAD cuts the ground of the main relay and the pre-charge relay.
If the cell is overcharged, the switch turns OFF and the vehicle cannot be driven.
RAD
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RAD on 10 cells
RAD on 14 cells
RAD Wiring Harness
Operation
Module
Normal
Failure
Current
ON (Connected)
OFF (Cut off)
RAD
-
Switch rise
High Voltage
Normal
Cut off
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Phenomenon
Normal
Failure on starting the motor and warning light
Diagram
EV Battery System
Circuit Diagram
EV Battery System
Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200.
1. Turn the ignition switch OFF and disconnect the auxiliary batter negative (-) terminal.
2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Prcedure")
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3. Remove the high voltage battery upper case.
(Refer to High Votlage Battery System - "Case")
4. Measure the combined resistance of RAD terminal.
Specification :Less than 3 Ω (20°C)
5. Measure the resistance of each RAD.
Specification :Less than 0.375Ω (20°C)
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When installing the RAD harness, be sure to check if the connector is installed on the correct position.
[If not correct]
1. Failure of precharging
2. RAD malfunction (misrecognize that the high voltage battery is swollen)
[Main inspection items]
1. Check that the RAD switch is facing down.
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2. Be careful not to reverse the battery No. 1 module RAD connector (2 pins) and the BMS extension connector (1 pin).
3. Be careful not to reverse the battery No. 8 module RAD connector (2 pins) and the BMS extension connector (1 pin).
EV Battery System
Specification
[14 cells LH/ RH]
Item
Specification
Resistance (Ω)
26 ~ 29
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[10 cells LH/ RH]
Item
Resistance (Ω)
Specification
16 ~ 18
EV Battery System
Component
1. High Voltage Battery Heater
2. High Voltage Battery Heater Relay
3. High Voltage Battery Heater Fuse
4. High Voltage Battery Heater Temperature Sensor
EV Battery System
Description
High Voltage Battery Heater is installed in every module and it is controlled by heater relay.
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High Voltage Flow
Control Flow
Operation
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EV Battery System
System Circuit Diagram
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EV Battery System
Inspection
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200.
1. Turn the ignition switch OFF.
2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repiar procedures - "Removal")
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4. Remove the high voltage battery pack upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
5. Measure the resistance.
14 cells LH/ RH
Item
Specification
Resistance (Ω)
26 ~ 29
Item
Specification
Resistance (Ω)
16 ~ 18
10 cells LH/ RH
LH
RH cell heater
Removal
High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are combined with High
Voltage Battery Pack Assembly. Refer to the removal procedure of high voltage battery pack assembly.
Installation
High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are combined with High
Voltage Battery Pack Assembly. Refer to the removal procedure of high voltage battery pack assembly.
EV Battery System
Specification
Item
Specification
Rated Voltage (V)
ON
Coil
450
Rated Current (A)
10
Voltage Drop (V)
Operation Voltage (V)
Less than 0.5 (200A)
12
Resistance (Ω)
104.4 ~ 127.6 (20°C)
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Item
Specification
Note
Heater Relay Switch Resistance (Ω)
∞
Checkable by multi tester
Heater Relay Operation Sound
Heater Relay Coil Resistance (Ω)
"Clicking"
104.4 ~ 127.6 (20°C)
Checkable by GDS and SST
Checkable by multi tester
EV Battery System
Component
1. Battery Heater
2. Battery Heater Relay
3. Battery Heater Fuse
4. Battery Heater Temperature Sensor
EV Battery System
Description
High Voltage Battery Heater Relay is installed in the Power Relay Assembly (PRA).
It supplies high voltage flow inside the heater to operate the heater to warm the high voltage battery.
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Control Flow
Operation
EV Battery System
System Circuit Diagram
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Circuit Diagram
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EV Battery System
Inspection
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100,
0K375-E4100, 0K375-E4200.
High Voltage Battery Heater Relay Switch Resistance
[Using multi tester (Relay OFF)]
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Inspect the high voltage high voltage battery heater relay by using multi tester when the relay is off
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")
3. Measure the resistance between the heater relay (+) switch terminal and the (+) power terminal which is connected to high voltage joint
box.
Specification :∞Ω(20°C)
[Using GDS (Relay ON)]
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
3. Connect the SST(0K918-E4100, 0K375-E4100, 0K375-E4200) to the vehicle.
4. Connect the GDS to DLC.
5. Turn the ignition swtich ON.
6. Activate the battery heater relay by using "Actuation Test" on the GDS as shown in the illustration below.
When the relay is ON, there is a relay operation sound.
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High Voltage Battery Heater Relay Coil Resistance
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")
3. Measure the resistance between the No.6 and No.7 of power relay assembly connector.
Specification :104.4 ~ 127.6 Ω
Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
Specification
Item
Current (A)
EV Battery System
Component
Specification
10
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1. High Voltage Battery Heater
2. High Voltage Battery Heater Relay
3. High Voltage Battery Heater Fuse
4. High Voltage Battery Heater Temperature Sensor
EV Battery System
High Voltage Battery Heater Fuse
It is connected to battery heater relay switch and it cuts off the circuit in case of overcurrent.
It is installed in the Power Relay Assembly (PRA).
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Operation
EV Battery System
System Circuit Diagram
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Circuit Diagram
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EV Battery System
Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
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Specification
Temperature (°C)
-40
Resistance (kΩ)
204.5
Tolerance (%)
±4.0
-30
117.8
±3.5
- 20
70.34
±3.0
- 10
43.43
±2.5
0
10
27.63
18.07
±2.0
±1.6
20
12.11
±1.2
30
40
8.303
5.813
±1.2
±1.5
50
4.149
±1.9
60
3.013
±2.2
70
2.225
±2.5
EV Battery System
Component
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1. High Voltage Battery Heater
2. High Voltage Battery Heater Relay
3. High Voltage Battery Heater Fuse
4. High Voltage Battery Heater Temperature Sensor
EV Battery System
Description
It senses the temperature to determine if the battery heater is operating well according to conditions.
EV Battery System
Circuit Diagram
EV Battery System
Inspection
High voltage battery heater temperature sensor is installed in modules No. 1 and No. 8.
1. Turn the ignition switch OFF.
2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repair procedures - "Removal")
4. Remove the high voltage battery pack upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) as shown in the image beow.
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6. Connect the GDS to DLC.
7. Turn the ignition switch ON.
8. Check the "Heater Temperature" in the GDS service data.
9. Turn the ignition switch OFF.
10. Disconnect the SST (High voltage battery cable & BMS terminal).
11. Check resistance for each temperature.
Temperature (°C)
Resistance (KΩ)
Tolerance (%)
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-40
204.5
-30
117.8
±4.0
±3.5
- 20
- 10
70.34
43.43
±3.0
±2.5
0
27.63
±2.0
10
18.07
±1.6
20
12.11
±1.2
30
8.303
±1.2
40
5.813
±1.5
50
4.149
±1.9
60
3.013
±2.2
70
2.225
±2.5
Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
Component
High Voltage Battery
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1. Cooling Fan
2. Outlet Cooling Duct
3. Protector Outlet Duct Panel
4. Battery Module Outlet Duct
5. Inlet Temperature Sensor
Vehicle
1. Cooling Fan Relay
EV Battery System
Description
The system temperature is calculated by the BMS based on 8 temperature sensor signals. And the cooling fan is conrolled in 9 steps to
maintain the normal temperature of high voltage battery system.
The air-cooling method is applied in the cooling system where indoor air is used to cool down the high voltage battery pack assembly.
Operation
Control Flow
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Air Flow
1. Cooling fan operates.
2. Indoor air flows into the cooling duct (inlet).
3. Cools down the high voltage battery in the direction of the arrows.
4. Air is ventilated out through the cooling duct (outlet).
EV Battery System
Specification
Cooling Fan Speed
Duty (%)
0
0
Fan Speed(rpm)
0
1
10
900
2
20
1200
3
30
1500
4
5
40
50
1800
2100
6
7
60
70
2450
2600
8
80
2800
9
90
3000
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EV Battery System
Description
It controls the BLDC motor speed by the PWM signal of BMS ECU.
EV Battery System
Inspection
1.
2.
3.
4.
Turn the ignition switch OFF and disconnect the auxiliary battery (12V) negative (-) terminal.
Connect the GDS to DLC.
Turn the ignition switch ON.
Inspect "Control Duty" and waveforms according to "Fan Status" by performing "Actuation Test" on GDS.
Cooling Fan Speed
0
Duty (%)
0
Fan Speed (rpm)
0
1
10
900
2
3
20
30
1200
1500
4
40
1800
5
6
50
60
2100
2450
7
70
2600
8
80
2800
9
90
3000
[Cooling Fan at 1st Speed]
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[Cooling Fan at 2nd Speed]
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[Cooling Fan at 3rd Speed]
[Cooling Fan at 4th Speed]
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[Cooling Fan at 5th Speed]
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[Cooling Fan at 6th Speed]
[Cooling Fan at 7th Speed]
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[Cooling Fan at 8th Speed]
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[Cooling Fan at 9th Speed]
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[Cooling Fan Stop]
Removal
1. Turn the ignition switch OFF and disconnect the auxiliary (12V) negative (-) terminal.
2. Remove the rear cushion.
(Refer to Body - "Rear Seat Assembly")
3. After loosening the nut (A), remove the protector outlet duct panel (B).
Protector outlet duct panel mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Open the trunk.
5. Remove the luggage board (A).
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6. After loosening the bolt (A), remove the outlet cooling duct (B).
Outlet cooling duct mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
7. After loosening the nut (A), remove the cooling fan (B).
Cooling fan mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Installation
1. Install in the reverse ordrer of removal.
EV Battery System
Description
It works as the air flow path when cooling fan operates.
Battery Module Outlet Duct
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Protector Outlet Duct Panel
Outlet Cooling Duct
EV Battery System
Removal
Battery Module Outlet Duct
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Remove the high voltage battery upper case.
(Refer to High Votlage Battery System - Case - "Upper Case")
2. After loosening the nut, remove the battery module outlet duct (A).
Battery module outlet duct mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Protector Outlet Duct Panel
1. Turn the ignition switch OFF and disconnect the auxiliary battery (12V) negative (-) terminal.
2. Remove the rear seat cushion.
(Refer to Body - "Rear Seat Assembly")
3. After loosening the nut (A), remove the protector outlet duct panel (B).
Protector outlet duct panel mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Outlet Cooling Duct
1. Turn the igntion swtich OFF and disconnect the auxiliary battery (12V) negative (-) termianl.
2. Remove the rear seat cushion.
(Refer to Body - Rear Seat Assembly")
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3. After loosening the nut (A), remove the protector outlet duct panetl (B).
Protector outlet duct panel mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Open the trunk.
5. Remove the luggage board (A).
6. After loosening the bolt (A), remove the outlet cooling duct (B).
Outlet cooling duct mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Installation
1. Install in the reverse order of removal.
EV Battery System
Specification
Temperature (°C)
-40
Resistance (KΩ)
204.5
Tolerance (%)
±4.0
-30
117.8
±3.5
- 20
70.34
±3.0
- 10
43.43
±2.5
0
27.63
±2.0
10
18.07
±1.6
20
12.11
±1.2
30
40
8.303
5.813
±1.2
±1.5
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50
4.149
±1.9
60
70
3.013
2.225
±2.2
±2.5
EV Battery System
Description
Inlet temperature sensor is installed on the No.8 module of high voltage battery and it detects the inner air temperature of battery. The
operation of cooling fan depends on the inlet temperature sensor value.
Inlet Temperature Sensor
Installation (on the No.8 battery module)
EV Battery System
Circuit Diagram
EV Battery System
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Inspection
1. Turn the ignitionswitch OFF.
2. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3. Remove the high voltage battery System assembly.
(Refer to High Voltage Battery System - Repair procedures - "Removal")
4. Remove the high voltage battery pack upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) as shown in the image below.
6. Connect the GDS to DLC.
7. Turn the ignition switch ON.
8. Check the "Battery Inlet Temperature" in the GDS service data.
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9. Turn the ignition switch OFF.
10. Disconnect the SST (high votlage battery cable & BMS check cable).
11. Check the resistance by the temperature.
Temperature (°C)
-40
Removal
Resistance (KΩ)
204.5
Tolerance (%)
±4.0
-30
117.8
±3.5
- 20
- 10
70.34
43.43
±3.0
±2.5
0
10
27.63
18.07
±2.0
±1.6
20
12.11
±1.2
30
8.303
±1.2
40
5.813
±1.5
50
4.149
±1.9
60
3.013
±2.2
70
2.225
±2.5
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High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are integrated into the high
voltage battery pack assembly. So refer to the removal procedure of high voltage battery pack assembly.
Installation
High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are integrated into the high
voltage battery pack assembly. So refer to the removal procedure of high voltage battery pack assembly.
EV Battery System
Components
1. On-Board Charger (OBC)
2. Rapid Charge Port
3. Normal Charge Port
4. High Voltage Battery
EV Battery System
Description
Electric vehicle can be charged by two methods, rapid charge and normal charge.
In the case of normal charge, the battery is charged after 220V AC power is transformed to DC power by On-Board Charger (OBC). In the
case of rapid charge, the DC power from charging station goes directly to the battery.
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While charging the vehicle, the driving of the vehicle is restricted logically for safety. And the vehicle cannot be charged by two charge
methods at the same time.
The logic is controlled by BMS ECU and IG relays #1,2,3.
IG 3 signal activates the Low Voltage DC-DC Converter (LDC), BMS ECU, Motor Control Unit (MCU), Vehicle Control Unit (VCU) and OnBoard Charger (OBC), and it enables the vehicle to be charged.
• IG3 Signal: It is the signal only for the Electric Vehicle. The signal goes to Low Voltage DC-DC Converter (LDC), BMS ECU, Motor
Control Unit (MCU), Vehicle Control Unit (VCU) and On-Board Charger.
• IG3 #1 Relay : When the high voltage controller operates, IG3 signal is provided through the IG3 #1 relay, except for normal or rapid
charge,.
• IG3 #2 Relay : In the case of normal charge, it operates to provide the IG3 signal.
• IG3 #3 Relay : In the case of rapid charge, it operates to provide the IG3 signal.
EV Battery System
Specification
Maximum Output
6.6kW
Output Density
0.52kVA/ℓ
Size
327 X 367 X 105 mm
ICCB
Approx. 1.4kW
EVSE
6.6kW
EV Battery System
Description
In normal charge, the battery is charged through the On-Board Charger (OBC) using external power supply of 220V.
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On-Board Charger (OBC) is the equipment that charges the high voltage battery of electric vehicle using the 110 ~ 220V AC power. Its
maximum output is 6.6 kW and the efficiency is about 91%.
Main Function
Control
Protect
Item
Control the input current power factor
Limit the maximum output
Troubleshooting
Cooperative
control
EV Battery System
Schematic Diagrams
Cooperative control the driving
Contents
To satisfy the AC power standar
• When exceeds the OBC maximum capacity
• When exceeds the OBC limit temperature
Detect the failure of OBC
Cooperative control with other system at pre scheduling
charge / air conditioning
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Input Connector (AC)
Terminal
Description
1
2
Phase voltage (L1)_220VAC
Ground
3
Phase voltage (L2)_220VAC
Specification
Current (normal)
Voltage (maximum)
33A
310VAC
Output Connector (DC)
Terminal
Description
1
High Voltage Battery (-)
2
3
High Voltage Battery (+)
High Voltage Interlock Pin
4
High Voltage Interlock Pin
Specification
Current (normal)
Voltage (maximum)
25A
495VDC
Signal Connector
Specification
Terminal
Description
1
Ground
0V
2
3
IG3
Connection sensing (EVSE)
18V
5V
4
Control Pilot (EVSE)
12V
5
6
Relay operation
CAN_Low
18V
1.5-2.5V
7
CAN-High
8
9
Charge state indication (Right)
Charge state indication (Center)
18V
18V
10
Charge state indication (Left)
18V
11
CP, PD Shielding ground
0V
12
Auxiliary 12V battery (+)
18V
EV Battery System
Current (normal)
1A
Voltage (maximum)
2.5-3.5V
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Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Remove the high voltage joint box.
(Refer to High Voltage Distribution System - "High Voltage Joint Box")
3. Drain the coolant by loosening the drain plug.
(Refer to Traction Motor System - "Coolant")
4. Disconnect the OBC cable connector (A) and OBC signal connector (B).
5. Loosen the connector bracket mounting bolt (C) and then remove the connector bracket (D) from the OBC.
6. Disconnect the OBC coolant hose (A).
7. Loosen the mounting bolt and then remove the reservoir tnak (A) from the OBC.
8. Loosen the A/C accumulator mounting bolt (A). (With Heat Pump)
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9. Loosen the OBC mounting bolt (A) and then remove the OBC.
Installation
1. Install the OBC in the reverse order of removal.
OBC mounting bolt : 1.0 ~1.2kgf.m
When injecting the coolant, perform the air bleeding by activating the EWP using GDS.
(Refer to Motor Cooling System - "Coolant")
EV Battery System
Specification
Output
100kW
DC 500V, 200A
50kW
DC 450V, 110A
EV Battery System
Description
Rapid charge charges the battery using high voltage on a quick charge stand.
The electric power goes directly to the battery through the rapid charge port. To protect the battery, it is charged up to 84% in the first charge,
and this can be recharged upto 95% in the second charge.
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Quick charge relay and PRA relay safely protect the rapid charge port by cutting the current to rapid charge port. The current flows through
the quick charge relay and the PRA relay only when the connector is connected to rapid charge port.
EV Battery System
Description
Charge port consists of normal charge port (1) and the rapid charge port (2) in the front of vehicle. The charge starts when the ICCB or the
quick charge coonnector is connected to charge port.
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1. Normal Charge Port
2. Rapid Charge Port
EV Battery System
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
Normal Charge Port
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Disconnect the auxiliary battery (12V) negative (-)terminal.
3. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
4. Disconnect the wiring harness connector (A) and then remove the normal charge connector (B) from the connector bracket (C).
5. Remove the normal charge wiring fixing clip (D) from the cooling fan shroud.
6. Disconnect the normal charge cable connector (A).
Disconnect the cable in the following order.
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7. Remove the normal charge port (A).
Tightening torque :10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 7.9 ~ 10.1 lb-ft)
8. Install in the reverse order of removal.
Rapid Charge Port
1. Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
2. Disconnect the auxiliary batter (12V) negative (-) terminal.
3. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
4. Disconnect the wiring harness connector (A) and then remove the normal charge connector (B) from the connector bracket (C).
5. Disconnect the rapid charge cable connector (A).
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Disconnect the cable in the following order.
6. Remove the rapid charge port (A).
Tightening torque :1.1 ~ 1.4 kgf.m
7. Install in the reverse order of removal.
EV Battery System
Components Location
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1. High voltage joint box
2. Air conditioning compressor high voltage connector
3. Electric power control unit (EPCU) high voltage cable
4. On-board charger (OBC) high voltage cable connector
5. PTC heater high voltage cable
6. High voltage battery assembly high voltage cable
7. High voltage joint box connector
8. Quick charge high voltage cable
EV Battery System
Description
Function: The high voltage joint box distribute high voltage to the each unit of vehicle.
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High-voltage power charge / output system flow
EV Battery System
Removal
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
• Do not remove the high voltage joint box cover. You will be killed or hurt.
• Do not disassemble the parts inside.
1. Remove the PE room cover (A).
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2. Disconnect the quick charge high voltage cable (A).
3. Disconnect the high voltage joint box connector (A).
4. Disconnect the air conditioner compressor high voltage connector (A).
5. Disconnect the high voltage battery cable (A).
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6. Disconnect the PTC heater high voltage connector (A).
7. Disconnect the EPCU high voltage cable (A).
8. Disconnect the on-board charger high voltage connector (A).
9. Remove the high voltage joint box (A) after loosening bolts.
Tightening torque :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Installation
1. Install in the reverse order of removal.
• If a high voltage connector is not connected make sure that the pins are bent.
• Do not insert to strong force a high-voltage connector.
EV Battery System
Components Location
1. 3-phase high voltage cable [MCU - Motor]
2. High voltage cable [High voltage battery - High voltage joint box]
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EV Battery System
Removal
[High voltage battery pack - High voltage joint box]
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system (Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries
1. Remove the PE room cover (A).
2. Disconnect the high voltage battery cable (A).
3. Remove the under cover (A).
Tightening torque :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the high voltage cable together with protector bracket from body of vehicle after loosening protector bracket nuts (A).
Tightening torque :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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5. Remove the under cover (A) of high voltage battery.
Tightening torque :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
6. Disconnect the high voltage cable (A) from the high voltage battery.
7. Remove the high voltage cable (A) together with protector bracket from body of vehicle after loosening protector bracket nut.
Tightening torque :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
[MCU - Motor]
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• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system (Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries
1. Remove the under cover (A) of high voltage battery.
Tightening torque :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
2. Remove the motor high voltage cable (A) from the motor and the MCU.
Installation
1. Install in the reverse order of removal.
• If a high voltage connector is not connected make sure that the pins are bent.
• Do not insert to strong force a high-voltage connector.
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Traction Motor System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Traction Motor System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Traction Motor System
Specifications
Motor
Item
Specifications
Type
Permanent magnet synchronous motor
(Internal permanent magnet)
Maximum output
81.4 kW
Rated power
42.7 kW
Maximum torque
285 N.m
Maximum rotational speed
9800 rpm
Rated output range
2730 ~ 8000 rpm
Operating temperature conditions
-40 ~ 105 °C (-40 ~ 221 °F)
Cooling method
Water cooling
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Electric Water Pump (EWP)
Item
Specifications
Type
Motor driven
Operating conditions
Speed control
Operating rotational speed
500 ~ 3740 rpm
Operating voltage
13.5 ~ 14.5 V
Capacity
Min. 12 lpm (at 0.6 bar)
Rated current
Below 2.5 A (at 14 V)
Operating temperature conditions
-20 ~ 105 °C (-4 ~ 221 °F)
Storage temperature conditions
-40 ~ 125 °C (-40 ~ 257 °F)
Coolant temperature
Below 75 °C (167 °F)
Coolant
Item
Specifications
Without heat pump
Approx. 4.1 ~ 4.2 L
(1.08 ~ 1.11 U.S.gal., 4.33 ~ 4.44 U.S.qt., 3.61 ~
3.70 lmp.qt.)
With heat pump
Approx. 4.6 ~ 4.7 L
(1.21 ~ 1.24 U.S.gal., 4.86 ~ 4.97 U.S.qt., 4.05 ~
4.14 lmp.qt.)
Coolant capacity
Tightening Torque
Motor & Gear Differential Unit
Quantity
N.m
kgf.m
lb-ft
Under cover mounting bolts
Item
6
7.8 ~ 11.8
0.8 ~ 1.2
5.9 ~ 8.7
Side cover mounting bolts
4
7.8 ~ 11.8
0.8 ~ 1.2
5.9 ~ 8.7
Power electric frame RH support bracket
bolts
2
78.5 ~ 98.1
8.0 ~ 10.0
57.9 ~ 72.3
Power electric frame RH support bracket nuts
4
78.5 ~ 98.1
8.0 ~ 10.0
57.9 ~ 72.3
Power electric frame LH support bracket
bolts
2
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Power electric frame LH support bracket nuts
2
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Motor mounting bracket through bolt
1
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
Motor mounting bracket bolt
3
63.7 ~ 83.4
6.5 ~ 8.5
47.0 ~ 61.5
Reduction gear mounting bracket through
bolt
1
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
Reduction gear mounting bracket bolts
3
63.7 ~ 83.4
6.5 ~ 8.5
47.0 ~ 61.5
Rear roll mounting bracket through bolt
1
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
Rear roll mounting bracket bolt
3
63.7 ~ 83.4
6.5 ~ 8.5
47.0 ~ 61.5
Motor Cooling System
Item
Quantity
N.m
kgf.m
lb-ft
2
4.9 ~ 7.8
0.5 ~ 0.8
3.6 ~ 5.8
Resistor mounting bolt
1
1.77 ~ 2.45
0.18 ~ 0.25
1.30 ~ 1.81
Cooling fan motor mounting bolt
3
3.9 ~ 5.9
0.4 ~ 0.6
2.9 ~ 4.3
Radiator upper bracket mounting bolt
4
8.8 ~ 10.8
0.9 ~ 1.1
6.5 ~ 8.0
Condenser bracket mounting bolt
2
5.9 ~ 9.8
0.6 ~ 1.0
4.3 ~ 7.2
Electric Water Pump (EWP) assembly
mounting bolt
3
8.8 ~ 10.8
0.9 ~ 1.1
6.5 ~ 8.0
Reservoir tank mounting bolt
2
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Cooling fan assembly mounting bolt
Traction Motor System
Motor Assembly
Overview
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Drive motor in EV is a system that generates drive power in a vehicle that does not have an engine. Accordingly, it generates high power
output for acceleration, uphill, and high speed driving with almost no sound. During deceleration, the motor acts as an alternator and
generates electricity to recharge the high voltage battery. This system improves fuel efficiency and increases driving distance. Drive force
generated by the motor is transferred to the wheels via reducer linked to the rotor shaft and the drive shaft.
Major Features of Drive Motor
• Power (Discharge) : Drive force is generated through electric energy stored in a battery.
• Regenerative Braking (Recharge): Kinetic energy created during deceleration is converted to electric energy by using the drive motor as
an alternator, and converted energy is used to recharge the battery.
Energy Flowchart
• When driving
• When the regenerative braking system operates
Traction Motor System
Troubleshooting
Failure
Overheat due to insufficient
coolant
Cause
– Excessive air in coolant channel
– Insufficient coolant
– Coolant leakage
Inspection Item
– Bleed air with GDS and refill coolant
– Hose clamping, radiator leakage, etc.
– Electric Water Pump (EWP), Cooling Fan
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Overheat due to component
malfunction
– Cooling Fan or Electric Water Pump (EWP)
failure
Overheating due to clogged
coolant channel
– Clogged coolant channel
Power Electric related component
failure
– High voltage cable disconnection
(High Voltage Junction Box - On Board Charger – High voltage cable connection
(OBC) - Electric Power Control Unit (EPCU) –
– Signal connector connection
Drive Motor)
– CAN Line wiring
– Disconnected signal connector
– Faulty CAN wiring insulation
Low insulation resistance
– Faulty power electric related component
– High Voltage Junction Box, On Board Charger
insulation
(OBC), Electric Power Control Unit (EPCU),
* If one component is not insulated, it may cause Drive Motor, High Voltage Cable
damage in another component.
Traction Motor System
Removal and Installation
1. Remove the power electric cover (A).
2. Install in the reverse order of removal.
Traction Motor System
Components
– Inside coolant channel
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1. Side cover (RH)
2. Under cover
Traction Motor System
Removal and Installation
Under Cover
1. Remove the under cover (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
3.Side cover (LH)
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2. Install in the reverse order of removal.
Side Cover
1. Remove the under cover.
2. Remove the side cover (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
[RH]
[LH]
3. Install in the reverse order of removal.
Traction Motor System
Components
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1. Power electric frame RH support bracket
2. Power electric frame LH support bracket
3. Motor mounting bracket
Traction Motor System
Removal and Installation
Power Electric Frame RH Support Bracket
1. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
2. Install the jack under the motor.
4. Reduction gear mounting bracket
5. Rear roll mounting bracket
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Put the rubber block between the jack and motor to avoid damaging the motor.
3. Remove the power electric frame RH support bracket (A).
Tightening torque :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
4. Install in the reverse order of removal.
Power Electric Frame LH Support Bracket
1. Remove the auxiliary 12V battery and auxiliary 12V battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
2. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
3. Install the jack under the reduction gear.
Put the rubber block between the jack and reduction gear to avoid damaging the reduction gear.
4. Remove the plug (A).
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5. Remove the power electric frame LH support bracket (A).
Tightening torque
Bolt (B) : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Bolt (C) : 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
6. Install in the reverse order of removal.
Motor Mounting Bracket
1. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
2. Install the jack under the motor.
Put the rubber block between the jack and motor to avoid damaging the motor.
3. Separate the reservoir tank (A) to obtain space for remove the motor mounting bracket bolt.
Tightening torque
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Separate the electric water pump (EWP) (A) to obtain space for remove the motor mounting bracket bolt.
Tightening torque :
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft)
5. Remove the motor mounting bracket (A).
Tightening torque
Bolt (B) : 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolt (C) : 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
6. Install in the reverse order of removal.
Reduction Gear Mounting Bracket
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1. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
2. Install the jack under the reduction gear.
Put the rubber block between the jack and reduction gear to avoid damaging the reduction gear.
3. Remove the Auxiliary 12V Battery and Auxiliary 12V Battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
4. Remove the reduction gear mounting bracket (A).
Tightening torque
Bolt (B) : 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolt (C) : 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
5. Install in the reverse order of removal.
Rear Roll Mounting Bracket
1. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
2. Install the jack under the motor.
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Put the rubber block between the jack and motor to avoid damaging the motor.
3. Remove the rear roll mounting bracket (A).
Tightening torque
Bolt (B) : 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolt (C) : 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
4. Install in the reverse order of removal.
Traction Motor System
Description
Drive motor for EV is a system that generates power in an electric vehicle that has no engine. It generates high power (285Nm) and torque
(81.4kW) to provide necessary force for acceleration, uphill, and high speed driving. In addition, it provides comfortable driving environment
since it does not generates engine noise. When decelerating, the motor acts as an alternator to generate electricity and recharges the
vehicle installed high voltage battery. This improves efficiency and increases drive distance. Drive force generated by the motor is
transferred to the wheels via reducer linked to the rotor shaft and the drive shaft.
Operation
When 3-Phase AC current is supplied to the coil, spinning magnetic field is generated and pulls the permanent magnet in the rotor coil to
generate rotation force.
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Traction Motor System
Components Location
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1. High voltage joint box
2. On-board charger (OBC)
3. Electric power control unit (EPCU)
[Inverter + Low DC/DC Converter (LDC) + Vehicle Control Unit
(VCU)]
Components
4. Motor
5. Reduction Gear
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1. Shaft
2. Ball-bearing
3. Retainer
4. Plate
5. Rotor core
6. Front cover
7. Stator core
8. Housing
9. Coil
10. Rear cover
11. Sensor cover
12. Motor position sensor [Resolver]
Traction Motor System
Removal and Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage circuit according to the “High Voltage Shut-off Procedures” before doing any work related with
the high voltage system to avoid serious electrical injuries.
• Use fender covers to avoid damaging painted surfaces.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
1. Shut off the high voltage circuit.
(Refer to Traction Motor System - "High Voltage Shut-off Procedures")
2. Remove the auxiliary 12V battery and auxiliary 12V battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
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3. Remove the power electric cover.
(Refer to Motor & Reduction Gear - "Power Electric Cover")
4. Remove the high voltage joint box.
(Refer to Battery Control System - "High Voltage Joint Box")
5. Remove the on-board charger (OBC).
(Refer to Battery Control System - "On-Board Charger (OBC)")
6. Remove the electric power control unit (EPCU).
(Refer to Vehicle Control System - "Electric Power Control Unit (EPCU)")
7. Disconnect the inhibitor switch connector (A).
8. Remove the shift cable (A) from the reduction gear.
Tightening torque :
Bolt (B) : 19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
Bolt (C) : 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
9. Remove the nut (A) and then separate the A/C pipe.
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
10. Remove the under cover and side cover.
(Refer to Motor & Reduction Gear - "Under Cover")
11. Drain the coolant.
(Refer to Motor Cooling System - "Coolant")
12. Recover the refrigerant.
(Refer to Heating, Ventilation, Air Conditioning - "Air Conditioning System")
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13. Disconnect the suction line (A) and discharge line (B) from the compressor.
[Without Heat Pump]
[With Heat Pump]
14. Remove the front driveshaft.
(Refer to Driveshaft and Axle - "Front Driveshaft")
15. Disconnect the coolant hose (A). [With Heat Pump]
16. Remove the bolts, and then separate the coolant 3way valve assembly (B). [With Heat Pump]
Tightening torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)
17. Disconnect the motor position and temperature sensor connector (A).
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18. Remove the motor mounting bracket bolt (A).
Tightening torque :
107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
19. Remove the reduction gear support bracket (A).
Tightening torque
Bolt (B) : 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolt (C) : 59.8 ~ 80.4 N.m (6.1 ~ 8.2 kgf.m, 44.1 ~ 59.3 lb-ft)
20. Remove the rear roll mounting bracket (A).
Tightening torque
Bolt (B) : 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolt (C) : 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
21. Support the motor & reduction gear assembly with a floor jack.
22. Remove the power electric frame RH support bracket (A).
Tightening torque :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
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23. Remove the plug (A).
24. Remove the power electric frame LH support bracket (A).
Tightening torque
Bolt (B) : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Bolt (C) : 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
25. Remove the motor & reduction gear assembly by lifting vehicle.
• Before removing the motor & reduction gear assembly, make sure hoses and wire connectors are disconnected.
• When removing the motor & reduction gear assembly, be careful not to damage any surrounding parts or body components.
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• Be careful not to damage high voltage connector.
26. Remove the motor support bracket (A).
Tightening torque :
53.0 ~ 60.8 N.m (5.4 ~ 6.2 kgf.m, 39.1 ~ 44.8 lb-ft)
27. Remove the reduction gear (A) from the motor.
Tightening torque :
42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
Cover the high voltage connector section with clean cloth or vinyl to keep out debris.
Inspection
[Phase Resistance]
1. Using a milliohm meter and check the resistance between lines (U, V, W).
Item
Resistance
(Line - Line)
[Insulation Resistance]
Inspection part
Specification
Remark
16.15 ~ 17.85 mΩ
Ordinary temperature
[20°C (68 °F)]
U-V
V-W
W-U
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1. Using a insulation resistance tester and check insulation resistance.
(1) Connect the negative terminal of insulation resistance tester to housing of the traction motor.
(2) Connect the positive terminal of insulation resistance tester to 3-phase (U, V, W) connector.
(3) Supply the DC 540V voltage through insulation resistance tester and then wait about 1 minute to measure the stable resistance
value.
Item
Inspection part
Specification
Remark
More than 10 MΩ
DC 540V, 1 minute
Housing - U
Insulation resistance
Housing - V
Housing - W
[Dielectric strength]
1. Using a withstanding voltage tester and check leakage current.
(1) Connect the negative terminal of withstanding voltage tester to housing of the traction motor.
(2) Connect the positive terminal of withstanding voltage tester to 3-phase (U, V, W) connector.
(3) Supply the AC 1600V voltage through withstanding voltage tester and then wait about 1 minute to measure the stable current value.
Item
Inspection part
Specification
Remark
Below 11 mA
AC 1600V, 1minute
Housing - U
Dielectric strength
Housing - V
Housing - W
Installation
1. Replace the new shaft O-ring (A).
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2. Apply the grease on the spline part (A).
If grease coating is not applied, clanking noise may occur when shifting to P range, and may reduce the durability of the spline.
3. Install the other parts reverse order of removal.
4. Connect the 3-phase power cable of U, V, W in the correct position.
If the power cable is incorrectly assembled, it may result in serious damage in inverter, drive motor, and high voltage battery. In
addition, it may also cause injury to driver or service engineer. As a result, take caution when assembling the power cable.
5. Fill the coolant and then check the leakage.
Refill the motor cooling system with coolant and then perform the air bleeding using the GDS.
(Refer to Motor Cooling System - "Coolant")
6. Install the motor assembly after Perform the "Initialization of Automatic Resolver Offset Calibration"
If "Initialization of Automatic Resolver Offset Calibration" is not reset after exchanging the motor, it may result in reduced max power
output as well as drive range.
(Refer to Motor & Reduction Gear - "Motor Position and Temperature Sensor")
Traction Motor System
Description
Motor Position Sensor
The accurate position of the rotor must be known at all times to ensure maximum output control of the motor. Like the CMP sensor on the
engine, it detects the position of the rotor in the motor.
Motor Temperature Sensor
The motor temperature has the large effect on the motor output. When the motor over heats, it’s IPM and stator coil may deform and their
performance may be affected. To prevent this, a temperature sensor is embedded in the motor to control the motor torque according to its
temperature.
Traction Motor System
Circuit Diagram
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Traction Motor System
Removal and Installation
1. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
2. Disconnect the motor position and temperature sensor connector (A).
3. Using a multi tester, measure the phase resistance.
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Test item
phase resistance
Test part
Motor position sensor
Motor temperature sensor
Inspection standard
R1-R2
26.5Ω ± 10 %
S1-S3
87.0Ω ± 10 %
S2-S4
76.0Ω ± 10 %
T1-T2
0.3118kΩ ± 3 %
Initialization of Automatic Resolver Offset Calibration
1. Turn ignition switch "OFF" and connect the GDS to the Data Link Connector.
2. P range & Turn ignition switch "ON" (Power button LED "Red"), Select "Vehicle S/W Management"
3. Perform the "Initialization of Automatic Resolver Offset Calibration".
Remarks
25°C (77 °F)
150°C (302 °F)
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Traction Motor System
Description
The motor, On-Board Charger (OBC), and Electric Power Control Unit (EPCU) that makes up the main system in EV generates high heat
when operating. Heat from these components can have negative effect on the performance of relevant parts. Furthermore, various
semiconductor parts in an EV may even melt due to high heat. As a result, proper cooling of these electrical units is essential. Electric Power
Control Unit (EPCU) monitors the operating temperature of various components and if necessary, activates the Electric Water Pump (EWP)
and circulates the coolant.
Coolant Flow
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Traction Motor System
Components
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1. Air guard
2. A/C condenser
3. Radiator
4. Cooling fan
5. Radiator upper hose
6. Radiator lower hose
7. Reservoir tank
Traction Motor System
Coolant Refilling And Bleeding
Never remove the reservoir cap when the high voltage system and electric device radiator is hot. Serious scalding could be caused by
hot fluid under high pressure escaping from the reservoir.
When pouring electric device coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If
any coolant spills, rinse it off immediately.
1. Make sure the electric device system and electric device radiator are cool to the touch.
2. Remove reservoir cap (A).
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3. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
4. Loosen the drain plug (A) and drain the coolant.
5. Tighten the radiator drain plug securely.
6. After draining engine coolant in the reservoir tank, clean the tank.
7. Fill the reservoir with water through the reservoir cap and tighten the cap.
To most effectively bleed the air, pour the water slowly and press on the upper/lower radiator hoses.
8. Connect a GDS and then operate the Electric Water Pump (EWP).
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9. Repeat steps 1 to 8 until the drained water runs clear.
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10. Fill fluid mixture with coolant and water (50%) slowly through the reservoir cap. Push the coolant hoses of the radiator so as bleed air
easily.
• Use only genuine antifreeze/coolant.
• For best corrosion protection, the coolant concentration must be maintained year-round at 55% minimum. Coolant
concentrations less than 55% may not provide sufficient protection against corrosion or freezing.
• For best corrosion protection, the coolant concentration must be maintained year-round at 55% minimum. Coolant
concentrations less than 55% may not provide • sufficient protection against corrosion or freezing.
• Do not mix different brands of antifreeze/coolants.
• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
11. Connect a GDS and then operate the Electric Water Pump (EWP).
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12. When the Electric Water Pump (EWP) operates and electric device coolant circulates, refill electric device coolant through the coolant
filling bottle.
13. When the operational sound volume of the Electric Water Pump (EWP) becomes small and when no air bubbles can be seen in the
coolant filling bottle. Bleeding of the electric device cooling system is completed.
After air bleeding is completed make sure that electric device coolant in the coolant filling bottle flow without air bubble during the
EWP actuation. If the electric device coolant flow is not seen or air bubbles are still seen, repeat steps 10 to 13.
14. After air bleeding is completed, stop the Electric Water Pump (EWP), add electric device coolant to the “F” level on the electric device
reservoir and install the electric device reservoir cap and the electric device reservoir cap.
It takes time to bleed out all the air in the cooling system. Refill coolant when coolant gets cool completely, when recheck the
coolant level in the reservoir tank for 2~3 days after replacing coolant.
Coolant capacity
Without Heat Pump : Approx. 4.1 ~ 4.2 L (1.08 ~ 1.11 U.S.gal., 4.33 ~ 4.44 U,S,qt., 3.61 ~ 3.70 lmp.qt)
With Heat Pump : Approx. 4.6 ~ 4.7 L (1.22 ~ 1.24 U.S.gal., 4.86 ~ 4.97 U,S,qt., 4.05 ~ 4.14 lmp.qt)
Traction Motor System
Components
[Without Heat Pump]
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1. Electric Water Pump (EWP) inlet hose
2. Reservoir tank
[With Heat Pump]
3. Reservoir tank
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1. Electric Water Pump (EWP) inlet hose
2. Reservoir tank
3. Reservoir tank lower hose
4. Radiator lower hose
Traction Motor System
Removal and Installation
1. Remove the power electric cover.
(Refer to Motor & Reduction Gear - "Power Electric Cover")
2. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
3. Drain the coolant.
(Refer to Motor Cooling System - "Coolant")
4. Remove the high voltage PTC heater cable fixing clip (A) from the reservoir tank.
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5. Disconnect the coolant hose from the reservoir tank.
[Without Heat Pump]
(1) Disconnect the radiator lower hose (A).
(2) Disconnect the Electric Water Pump (EWP) inlet hose (B).
[With Heat Pump]
(1) Disconnect the radiator lower hose (A).
(2) Disconnect the Electric Water Pump (EWP) inlet hose (B).
(3) Disconnect the reservoir tank lower hose (C).
6. Remove the reservoir tank (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
[Without Heat Pump]
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[With Heat Pump]
When installing the reservoir tank, insert the hook to the insert hole of on-board charger (OBC).
7. Install in the reverse order of removal.
8. Fill the reservoir with coolant.
(Refer to Motor Cooling System - "Coolant")
Refill the motor cooling system with coolant and then perform the air bleeding using the GDS.
(Refer to Motor Cooling System - "Coolant")
Inspection
Reservoir Cap
1. Remove the reservoir cap, wet its seal with coolant, and then install it on a pressure tester.
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2. Apply a pressure of 93.16 ~ 122.58 kPa (0.95 ~ 1.25 kg/cm², 13.51 ~ 17.78 psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the reservoir cap.
Reservoir Leakage Test
1. Wait until electric device system and electric device radiator are cool, then carefully remove the reservoir cap and fill the reservior with
motor coolant, then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
3. Inspect for motor coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the reservoir cap.
Traction Motor System
Description
The cooling fan operates in 2 stages (HIGH/LOW). The electric power control unit (EPCU) controls the cooling fan according to the coolant
temperature, vehicle speed and A/C operation.
[Cooling fan operation conditions]
A/C switch
A/C pressure
Vehicle speed
Coolant temperature
[kgf/cm² G (psi G)]
[km/h (mph)]
[°C (°F)]
V < 45 (28)
OFF
ON
ㅡ
P < 6 (85.3)
45 (28) ≤ V < 80 (49.7)
LOW
100 (212) or above
HIGH
95 ~ 100 (203 ~ 212)
LOW
100 (212) or above
HIGH
105 (221) or above
HIGH
All
105 (221) or above
HIGH
45 (28) ≤ V < 80 (49.7)
80 (49.7) ≤ V
12 (170.7) ≤ P < 15.5
(120.5)
95 ~ 100 (203 ~ 212)
80 (49.7) ≤ V
V < 45 (28)
6 (85.3) ≤ P < 12 (170.7)
Cooling fan speed
V < 45 (28)
45 (28) ≤ V < 80 (49.7)
45 ~ 100 (113 ~ 212)
LOW
100 (212) or above
HIGH
95 ~ 100 (203 ~ 212)
LOW
100 (212) or above
HIGH
105 (221) or above
HIGH
-30 ~ 95 (-22 ~ 203)
LOW
95 (203) or above
HIGH
95 ~ 100 (203 ~ 212)
LOW
100 (212) or above
HIGH
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15.5 (120.5) ≤ P
80 (49.7) ≤ V
105 (221) or above
HIGH
All
-30 (-22) or above
HIGH
Traction Motor System
Components
1. Cooling fan mounting retainer
2. Torque washer
3. Cooling fan
4. Fan motor
5. Cooling fan shroud
6. Cooling fan resistor
Traction Motor System
Specifications
Item
Specification
Fan type
PULLER
Fan speed control
Air flow rate [㎥/h (yd³/h)]
1,760 (2,302) -8% min.
Resistor
Fan speed (rpm)
1,960 ± 8%
Current (A)
12.5 + 10% max.
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Traction Motor System
Circuit Diagram
Traction Motor System
Removal and Installation
Cooling fan assembly
1. Disconnect the Auxiliary 12V Battery negative terminal.
2. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
3. Disconnect the wire harness connector (A) and then remove the motor connector (B) from the connector bracket (C).
4. Remove the normal charge wiring fixing clip (D) from cooling fan shroud.
5. Separate the radiator upper hose (A) from the hose fixing bracket (B).
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6. Remove the cooling fan assembly mounting bolt (A).
Tightening torque :
4.9 ~ 7.9 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 lb-ft)
[RH]
[LH]
7. Remove the cooling fan (A) from the vehicle.
8. Install in the reverse order of removal.
Resistor
1. Disconnect the resistor connector (A).
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2. Remove the resistor (A) from the cooling fan shroud.
Tightening torque :
1.8 ~ 2.5 N.m (0.18 ~ 0.25 kgf.m, 1.3 ~ 1.8 lb-ft)
3. Install in the reverse order of removal.
Disassembly
1. Remove the cooling fan (A) from the cooling fan assembly.
2. Disconnect the resistor connector (A).
3. Remove the fan motor (A) from the cooling fan shroud.
Tightening torque :
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3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
4. Install in the reverse order of removal.
Inspection
Fan Motor
1. Disconnect the fan motor connector from the resistor.
2. Connect the battery voltage to the "+" terminal and ground to "-" terminal.
3. Check the cooling fan motor operates well.
Traction Motor System
Components
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1. Radiator
2. Mounting insulator
3.Radiator upper bracket (LH)
4. Radiator upper bracket (RH)
5. Radiator lower hose
6. Radiator upper hose
Traction Motor System
Removal and Installation
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage circuit according to the “High Voltage Shut-off Procedures” before doing any work related with
the high voltage system to avoid serious electrical injuries.
1. Shut off the High Voltage circuit.
(Refer to Traction Motor System - "High Voltage Shutoff Procedure")
2. Disconnect the Auxiliary 12V Battery negative terminal.
3. Remove the power electric cover.
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(Refer to Motor & Reduction Gear - "Power Electric Cover")
4. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
5. Drain the coolant.
(Refer to Motor Cooling System - "Coolant")
6. Remove the cooling fan.
(Refer to Motor Cooling System - "Cooling Fan")
7. Disconnect the quick charge cable (A) and normal charge cable (B).
Disconnect the quick charge cable and normal charge cable as the procedures below.
[Quick charge cable]
[Normal charge cable]
8. Disconnect the radiator upper hose (A).
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9. Disconnect the radiator lower hose (A).
10. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
11. Disconnect the condenser connector (A). [Heat Pump Type]
12. Remove the ambient temperature sensor (A).
13. Remove the air guards (A).
[RH]
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[LH]
14. Remove charging cable mounting bracket (A).
Tightening torque :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
15. Remove the radiator upper bracket (A).
Tightening torque :
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft)
[RH]
[LH]
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16. Remove the condenser mounting bracket bolt (A).
Tightening torque :
5.9 ~ 9.8 N.m (0.6 ~ 1.0 kgf.m, 4.3 ~ 7.2 lb-ft)
[RH]
[LH]
17. Separate the condenser from the radiator.
18. Pull the radiator (A) upward and remove it from motor room.
19. Install in the reverse order of removal.
20. Fill the reservoir with coolant.
(Refer to Motor Cooling System - "Coolant")
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Refill the motor cooling system with coolant and then perform the air bleeding using the GDS.
(Refer to Motor Cooling System - "Coolant")
Traction Motor System
Description
• The Electric Water Pump (EWP) circulates coolant of the cooling circuit for the Motor system [Electric Power Control Unit (EPCU), Motor,
On-Board Charger (OBC)].
• When the Motor system coolants temperature rise over the threshold [set in the Electric Power Control Unit (EPCU)], Electric Power
Control Unit (EPCU) sends the command signal to Electric Water Pump (EWP) by CAN communication to operate Electric Water Pump
(EWP), and the temperature below the set value then sends stop signal. Electric Water Pump (EWP) sends the status information of
itself to Electric Power Control Unit (EPCU) whether Electric Water Pump (EWP) is in fail or not by CAN communication
• Coolant Flow
Traction Motor System
Components
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1. Electric Water Pump (EWP) inlet hose
2. Electric Water Pump (EWP) outlet hose
3. Electric Water Pump (EWP)
4. Electric Water Pump (EWP) upper bracket
5. Electric Water Pump (EWP) upper rubber pad
6. Electric Water Pump (EWP) upper rubber pad
7. Electric Water Pump (EWP) lower bracket
Traction Motor System
Specifications
Item
Specification
Construction
Motor Drive
Operation condition
Speed control
Speed
500 ~ 3740 rpm
Voltage (V)
13.5 ~ 14.5 V
Capacity
min. 12 lpm (0.6 bar)
Rated current (A)
Below 2.5 A (14 V)
Operation temperature
-20 ~ 105 °C
Storage temperature
-40 ~ 125 °C
Coolant temperature
Below 75 °C
Traction Motor System
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Removal and Installation
1. Disconnect the Auxiliary 12V Battery negative terminal.
2. Remove the under cover.
(Refer to Motor & Reduction Gear - "Under Cover")
3. Drain the coolant.
(Refer to Motor Cooling System - "Coolant")
4. Disconnect the electric water pump (EWP) connector (A).
5. Disconnect the electric water pump (EWP) inlet hose (B).
6. Disconnect the electric water pump (EWP) outlet hose (C).
7. Remove the electric water pump (EWP) assembly (A).
Tightening torque :
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft)
8. Install in the reverse order of removal.
9. Fill the reservoir with coolant.
(Refer to Motor Cooling System - "Coolant")
Refill the motor cooling system with coolant and then perform the air bleeding using the GDS.
(Refer to Motor Cooling System - "Coolant")
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Reduction Gear System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Page 3 sur 34
Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
Page 4 sur 34
Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Reduction Gear System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Reduction Gear System
Specifications
Item
Specifications
Reduction gear ratio
8.206
Maximum torque
285 Nm
Maximum RPM
10500 RPM
Tightening Torques
Item
N.m
kgf.m
lb-ft
Reduction gear mounting bolt
42.2 ~ 53.9
4.3 ~ 5.5
31.1 ~ 39.8
Reduction gear front mounting bolt
63.7 ~ 83.4
6.5 ~ 8.5
47.0 ~ 61.5
Reduction gear front bracket
bolts / nut
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
63.7 ~ 83.4
6.5 ~ 8.5
47.0 ~ 61.5
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Reduction gear rear bracket bolts /
nut
Manual control lever mounting
bolts
9.8 ~ 13.7
1.0 ~ 1.4
7.2 ~ 10.1
Inhibitor switch mounting bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Shift cable bracket mounting bolt
19.6 ~ 16.5
2.0 ~ 2.7
14.5 ~ 19.5
Shift lever assembly mounting bolt
9.8 ~ 13.7
1.0 ~ 1.4
7.2 ~ 10.1
Lubricants
Item
Reduction gear fluid
Specified lubricant
Quantity
SAE 75W/API 85,GL-4
1.2 ~ 1.4 L (0.317 ~ 0.370 U.S gal., 1.27 ~
1.48 U.S.qt., 1.06 ~ 1.23 Imp.qt.)
Illustration
Description
Reduction Gear System
Special Service Tools
Tool Name / Number
Oil seal installer
A: 09365-E1100 (Installer)
B: 09231-H1100 (Handle)
Installation of transaxle case oil seal.
Inhibitor switch guide pin
0K948-E4000
Inhibitor neutral fixed.
Commercial Tool
Tool Name
Auto bar
Reduction Gear System
Component
Illustration
Description
Used for holding motor assembly when
removing / installing gear drive unit
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1. Differential Oil Seal
2. Oil Filler Plug
Reduction Gear System
Inspection
1. Lift the vehicle.
2. Remove the under cover.
(Refer to Traction Motor System - "under cover")
3. Remove the oil filler plug (A).
3. Oil Drain Plug
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4. Check the oil condition and then oil level (A).
If the oil level is low, supplement the oil up to filler plug hole.
5. Install the oil filler plug (A).
Must replace with new gasket when installing the drain plug.
Replacement
Gear differential unit system does not need to be replaced for Normal Usage. If the vehicle is used for any of the Severe Usage
conditions listed below, replace the 120,000 miles. Severe usage is defined as
• Driving in rough road (Bumpy, Gravel, Snowy, Unpaved road, etc)
• Driving in mountain road, ascent/descent
• Repetition of short distance driving
• More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F) .
• Police, Taxi, Commercial type operation or trailer towing, etc
1. Using the lift raise the car.
2. Remove the under cover.
(Refer to Traction Motor System - "under cover")
3. Remove the drain plug (A) and drain the oil totally and then reinstall the drain plug.
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Must replace with new gasket when installing the drain plug.
4. Remove the oil filler plug (A).
5. Supplement up to oil filler plug hole.
6. Install the oil filler plug (A).
7. Install the under cover.
(Refer to Traction Motor System - "under cover")
Reduction Gear System
Description
Page 14 sur 34
• The role of reduction gear is similar to transmission. But unlike the transmission which has various gear ratio, the reduction gear
transfers the motor power with fixed reduction gear ratio.
• The reduction gear increases the torque by reducing the motor speed.
• There are 5 gears inlcuding parking gear in the inner of reduction gear and the MT oil is used for reduction gear. And no need to change
the oil.
Reduction Gear System
Components Location
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1. Motor assembly
Components
2. Reduction Gear
Page 16 sur 34
1. Differential Oil Seal
2. Oil Filler Plug
3. Oil Drain Plug
Reduction Gear System
Removal
• Use the fender cover to prevent the damage on the painting.
• Disconnect the connector & wiring to prevent the damage.
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Shut off the high voltage.
(Refer to Reduction Gear System. - " High Voltage Shut-off Procedures")
2. Remove the auxiliary 12V battery and auxiliary 12V battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
3. Remove the power electric cover.
(Refer to Traction Motor System - "Power Electric Cover")
4. Remove the high voltage joint box.
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(Refer to EV Battery System - "High voltage joint box")
5. Remove the on-board charger (OBC).
(Refer to Battery Control System - "On-Board Charger (OBC)")
6. Remove the electric power control unit (EPCU).
(Refer to Vehicle Control System - "Electric Power Control Unit (EPCU)")
7. Disconnect the inhibitor switch connector (A).
8. Remove the shift cable (C) by loosening the bolts (A) and nut (B).
Tightening torque:
(A): 19.6 ~ 16.5 N.m ( 2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
(B): 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
9. Remove the nut (A) and then separate the A/C pipe.
Tightening torque:
7.8 ~ 11.8 N.m ( 0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)
10. Remove the reduction gear upper mounting bolts (A).
Tightening torque:
42.2 ~ 53.9 N.m ( 4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
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11. Remove the front mounting bracket upper mounting bolt (A).
Tightening torque:
63.7 ~ 83.4 N.m ( 6.5 ~ 8.5kgf.m, 47.0 ~ 61.5 lb-ft)
12. Remove the electric A / C compressor.
(Refer to Heating,Ventilation And Air Conditioning - "Electric A / C Compressor")
13. Fix motor by using the auto bar (A).
14. Remove the drive shaft.
(Refer to Driveshaft and axle - "Front Driveshaft")
15. Fix reduction gear, and then remove the reduction gear lower mounting bracket mounting bolts (A) and (B) .
Tightening torque:
(A): 63.7 ~ 83.4 N.m ( 6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
(B): 42.2 ~ 53.9 N.m ( 4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
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16. Remove the reduction gear mounting bracket (C).
Tightening torque:
(A): 107.9 ~ 127.5 N.m ( 11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
(B): 63.7 ~ 83.4 N.m ( 6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
17. Remove the reduction gear lower mounting bolts (A).
Tightening torque:
42.2 ~ 53.9 N.m ( 4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
18. Remove the reduction gear by using the jack.
Installation
1. Install in the reverse order of removal.
If oil leak happens by damage on the oil seal, replace with new oil seal.
When installing the oil seal, use the oil seal installer(09365-E1100).
2. Reduction gear oil supplement by install the reduction gear.
(Refer to Reduction Gear Assembly - "oil")
3. Fill the reservoir with coolant.
(Refer to Motor Cooling System - "Coolant")
Reduction Gear System
Description
Page 20 sur 34
Inhibitor Switch monitors the lever's position(P, R, N, D) and is used to control gear setting signals.
Reduction Gear System
Specifications
▷ Type: Combination of output signals from 4 terminals
Power supply (V)
12
Output type
Combination of output signals
Signal Code Table
P
P-R
R
R-N
N
N-D
D
S1
12V
12V
0
0
0
0
0
S2
0
12V
12V
12V
0
0
0
S3
0
0
0
12V
12V
12V
0
S4
0
0
0
0
0
12V
12V
Reduction Gear System
Circuit Diagram
Page 21 sur 34
Reduction Gear System
Inspection
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.
Power Circuit Inspection
1. Disconnect the Inhibitor switch connector.
2. Ignition KEY "ON"" & Engine "OFF".
3. Measure voltge between supplied power and ground at inhibitor circuit.
Specification : Approx. 12V
Signal Circuit Inspection
1. Connect the Inhibitor switch connector.
2. Ignition KEY "ON" & Engine "OFF".
3. Measure voltages between each terminal and chassis ground during shift lever changed "P, R, N, D".
Specification : See below "Signal Code Table"
Signal Code Table
P
P-R
R
R-N
N
N-D
D
Signal "1"
12V
12V
0
0
0
0
0
Signal "2"
0
12V
12V
12V
0
0
0
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Signal "3"
0
0
0
12V
12V
12V
0
Signal "4"
0
0
0
0
0
12V
12V
Removal
• Use the fender cover to prevent the damage on the painting.
• Disconnect the connector & wiring to prevent the damage.
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Place the shift lever into the "N" position.
2. Shut off the high voltage.
(Refer to Reduction Gear System. - " High Voltage Shut-off Procedures")
3. Remove the auxiliary 12V battery and auxiliary 12V battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
4. Remove the power electric cover.
(Refer to Traction Motor System - "Power Electric Cover")
5. Remove the high voltage joint box.
(Refer to EV Battery System - "High voltage joint box")
6. Remove the on-board charger (OBC).
(Refer to Battery Control System - "On-Board Charger (OBC)")
7. Remove the electric power control unit (EPCU).
(Refer to Vehicle Control System - "Electric Power Control Unit (EPCU)")
8. Disconnect the inhibitor switch connector (A).
9. Remove the shift cable (C) by loosening the bolts (A) and nut (B).
10. Loosen the nut (A) and then remove the manual control lever (B).
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11. Loosen the nut (B) and then remove the inhibitor switch(A).
Installation
1. Place the shift lever into the "N" position.
2. Install the inhibitor switch (A) and then tighten the bolt (B).
Fasten the bolt loosely to adjust.
3. Install the manual control lever (B) and then tighten the nut (A)..
Fasten the bolt loosely to adjust.
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4. Align the hole (A) in the manual control lever with the "N" position hole (B) of the inhibitor switch and then insert the SST inhibitor switch
guide pin (0K948-E40000).
5. Tighten the nut (A) and the bolt 2 ea (B) with the specific torque.
Tightening torque:
(A): 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
(B): 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. Remove the SST (0K948-E40000).
7. Connect the inhibitor switch connector (A).
8. Install the shift cable and then tighten the nut (B).
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Fasten the bolt loosely to adjust.
9. Push the shift cable adhere to the direction of the arrow and then tighten the nut.
Tightening torque:
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 7.2 ~ 10.1 lb-ft)
10. Install the electric power control unit (EPCU).
(Refer to Vehicle Control System - "Electric Power Control Unit (EPCU)")
11. Install the on-board charger (OBC).
(Refer to Battery Control System - "On-Board Charger (OBC)")
12. Install the high voltage joint box.
(Refer to EV Battery System - "High voltage joint box")
13. Install the power electric cover.
(Refer to Traction Motor System - "Power Electric Cover")
14. Install the auxiliary 12V battery and auxiliary 12V battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
15. Install the high voltage.
(Refer to Reduction Gear System. - " High Voltage Shut-off Procedures")
Reduction Gear System
Components
Page 26 sur 34
1. Shifter lever assembly
2. Shift cable retainer
3. Shift cable assembly
4. Key inter lock switch
5. Manual mode switch housing
6. Shift lock solenoid
Reduction Gear System
Removal
1. Remove the shift lever knob & boots assembly (A) by Pulling in the upside.
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2. Remove the floor console assembly.
(Refer to Body - "Floor Console Assembly ")
3. Disconnect the shift lever switch connector (A).
4. Remove the wiring fastener (A) from the shift lever assembly.
5. Seperate the lever pin (B) and then remove the shift cable (A).
6. Remove the shift lever assembly (B) by loosening the bolts (A).
Tightening torque:
1.0 ~ 1.4 kgf.m
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7. Install in the reverse order of removal.
When installing, set room side shift lever and T/M side lever to "N" position.
Replacement
Shift lock solenoid replacement
1. Remove the plastic bracket (B) by loosening the screw (A).
2. Remove the shift lock solenoid (A) from the shift lever assembly.
3. Disconnect the key inter lock switch (B) by removeing the plastic bracket (A).
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4. Disconnect the shift lever main connector (A).
5. Remove the wiring fixed bracket in the main connector.
6. Remove the shift lock solenoid wiring from the main connector
Be sure to check the wiring color before disconnecting the wiring.
Pin
Function
3
Shift lock solenoid (-)
4
Shift lock solenoid (+)
9
Key inter lock switch (-)
10
Key inter lock switch (+)
Key inter lock switch
1. Remove the plastic bracket (B) by loosening the screw (A).
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2. Remove the shift lock solenoid (A) from the shift lever assembly.
3. Disconnect the key inter lock switch (B) by removing the plastic bracket (A).
4. Disconnect the shift lever main connector (A).
5. Remove the wiring fixed bracket in the main connector.
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6. Remove the shift lock solenoid wiring from the main connector
Be sure to check the wiring color before disconnecting the wiring.
Reduction Gear System
Components
Pin
Function
3
Shift lock solenoid (-)
4
Shift lock solenoid (+)
9
Key inter lock switch (-)
10
Key inter lock switch (+)
Page 32 sur 34
1. Shifter lever assembly
2. Shift cable retainer
3. Shift cable assembly
4. key inter lock switch
5. Manual mode switch housing
6. Shift lock solenoid
Reduction Gear System
Removal
• Use the fender cover to prevent the damage on the painting.
• Disconnect the connector & wiring to prevent the damage.
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1. Remove the shift lever knob & boots assembly (A) by Pulling in the upside.
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2. Remove the floor console assembly.
(Refer to Body - "Floor Console Assembly ")
3. Seperate the lever pin (B) and then remove the shift cable (A).
4. Remove the retainer (A) by loosening the nuts (B).
Tightening torque:
9.8 ~ 13.7 N.m ( 1.0 ~ 1.4 kgf.m, 7.2 ~ 10.1 lb-ft)
5. Shut off the high voltage.
(Refer to Reduction Gear System. - " High Voltage Shut-off Procedures")
6. Remove the auxiliary 12V battery and auxiliary 12V battery tray.
(Refer to Vehicle Control System - "Auxiliary 12V Battery")
7. Remove the power electric cover.
(Refer to Traction Motor System - "Power Electric Cover")
8. Remove the high voltage joint box.
(Refer to EV Battery System - "High voltage joint box")
9. Remove the on-board charger (OBC).
(Refer to Battery Control System - "On-Board Charger (OBC)")
10. Remove the electric power control unit (EPCU).
(Refer to Vehicle Control System - "Electric Power Control Unit (EPCU)")
11. Disconnect the inhibitor switch connector (A).
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12. Remove the shift cable (C) by loosening the bolts (A) and nut (B).
Tightening torque:
(A): 19.6 ~ 16.5 N.m ( 2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
(B): 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
13. Remove the shift cable by pulling it toward the interior.
Installation
1. Install in the reverse order of removal.
Install the cable after placing the shift lever and the transaxle manual control lever in the N position.
Page 1 sur 33
Vehicle Control System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to
“High Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety
accidents(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing personal protective equipment to touch the high voltage system. High voltage
components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor,
Power Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery
Current Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power
Control Unit (EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name
Insulation gloves
Illustration
Description
Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Insulation clothes
Used when inspecting or working on the high voltage
components
Insulation helmet
Safety glasses
Used in the following cases :
• During Removal & installation or inspection of the high
voltage battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
Insulation mat
Insulation sheet
Warning tape
All removed high voltage components are placed on an
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to
protect people not wearing personal protective equipment from
safety accidents.
Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.
• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
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• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high
voltage battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
Vehicle Control System
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.
Failure to follow the safety instructions may result in serious electrical injuries.
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High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
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5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
(3) Remove the high voltage cable (A).
(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
Vehicle Control System
Description
Electric vehicle is a vehicle that drives on electric energy. Unlike combustion engine vehicle, it does not use fossil fuel to generate drive force
but uses the electric energy stored in the high voltage battery mounted in the vehicle to power the vehicle. While combustion engine vehicle
generates emission gas, electric vehicle is an eco-friendly vehicle that has zero emission.
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Electric vehicle operation principle and recharge method
Motor Drive Control
• VCU: Calculates motor torque command with consideration to usable battery power, usable motor torque, and driver demand (APS,
Brake SW, Shift Lever).
• BMS: Provides usable battery power and SOC data for calculating motor torque command by VCU.
• MCU: Provides usable motor torque for calculating motor torque command by VCU.
Creates Inverter PWM signal to generate motor torque command received from VCU.
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Regenerative Brake Control
• AHB: Calculates total brake force based on driver demand (BPS) and then divides the force into hydraulic brake force and demanded
regenerative brake force.
Monitors the regenerative braking result (VCU) and compensates hydraulic brake force.
• VCU: Calculates motor recharge torque command for regenerative braking by considering demanded regenerative brake force (AHB),
usable battery power (BMS), and usable motor torque, and calculates the actual regenerative brake force by using the actual motor
output torque (MCU).
• BMS: Provides usable battery power and SOC data.
• MCU: Provides usable motor torque and actual motor output torque data.
Creates Inverter PWM signal to generate motor torque command received from VCU.
A/C Load Control
• FATC: Sends AC/PTC power request to VCU when driver demands cooling/heating (AC SW).
A/C load is controlled within the power range allowed by VCU.
• BMS: Provides usable battery power and SOC data.
• VCU: Sends final FATC allowed power by using the battery information and FATC requested power data.
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Electric load power (12V) supply
• BMS: Provides usable battery power and SOC data.
• VCU: Determines LDC ON/OFF and operation mode based on the battery information and vehicle status.
• LDC: Converts high voltage into low voltage based on the command from VCU, and supplies power to vehicle's electric components
(same function as an alternator).
DTE (Distance To Empty)
Calculates Distance To Empty
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Vehicle Control System
Schematic Diagram
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Vehicle Control System
Specification
Item
Specification
Input Voltage
240 ~ 413V
Operation Voltage
9 ~ 16V
Cooling Type
Water Cooled
Coolant Inflow Temperature
Max. 65 °C
Operation Temperature
-40 ~ 85 °C
Preservation Temperature
-40 ~ 85 °C
Vehicle Control System
Components and Components Location
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1. Electric Power Control Unit (EPCU)
[ Inverter + LDC + VCU]
Vehicle Control System
Description
Electric Power Control Unit (EPCU) is a 80kW power transformer system. It is integrated with inverter, LDC, and VCU.
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- Inverter: It's a system that converts DC power from the high voltage battery to AC power supplied to the vehicle's drive motor.
- LDC (converter): It's a system that converts DC power from the high voltage battery to DC power (low voltage) for the vehicle's electric
components.
Vehicle Control System
Removal
• Use a fender cover to prevent damage on body paint.
• Take caution not to damage the connector and wiring when disconnecting.
• Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
Mark to prevent faulty connection between wiring connector and hose.
1. Shut off the high voltage.
(Refer to Vehicle Control System - "High Voltage Shut-off Procedures")
2. Remove the Auxiliary 12V Battery and tray.
(Refer to EPCU - "Auxiliary 12V Battery ")
3. Remove the power electric cover.
(Refer to Traction Motor System - "Power Electric Cover" )
4. Remove the high voltage joint box.
(Refer to High Voltage Distributing System - "High voltage joint box" )
5. Remove the ON-Board Charger (OBC).
(Refer to High Voltage Charging System - "OBC")
6. Disconnect the electric water pump outlet hose (A) and electric power control unit & Motor hoses(B).
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7. Disconnect the electric power control unit connector (A).
8. Disconnect the Low Voltage DC/DC Converter "-" cable (A) and "+" cable (B).
Tightening torque :1.1 ~ 1.4 kgf.m
9. Disconnect the electric power control unit side power cable connector (A).
10. Remove chiller (A) after loosening the mounting bolts.
Tightening torque :0.8 ~ 1.2 kgf.m
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11. Remove the electric power control unit (A).
Tightening torque :5.0 ~ 6.5 kgf.m
Installation
1. Install in the reverse order of removal.
2. Connect the 3-phase power cable of U, V, W in the correct position.
If the power cable is incorrectly assembled, it may result in serious damage in inverter, drive motor, and high voltage battery. In
addition, it may also cause injury to driver or service engineer. As a result, take caution when assembling the power cable.
3. Fill the coolant and then check the leakage.
Refill the motor cooling system with coolant and then perform the air bleeding using the GDS.
(Refer to Motor Cooling System - "Coolant")
4. Install the motor assembly then perform "Initialization of Automatic Resolver OffsetCalibration" procedure.
If "Initialization of Automatic Resolver Offset Calibration" is not reset after exchanging the motor, it may result in reduced max power
output as well as drive range.
(Refer to Motor & Reduction Gear - "Motor Position and Temperature Sensor")
Vehicle Control System
Description
The inverter drives the motor of an Electric Vehicle (EV). It changes the DC current of the high voltage battery to the AC current require to
drive the motor.
That is, it converts the DC power (+, -) from the high voltage battery into 3-phase AC power (U, V, W) and controls it vis the signal from the
control board to drive the motor.
During acceleration, the high voltage battery provides additional power to the motor. During deceleration, the energy generated by the motor
is used to charge the high voltage battery and there by increase the driving distance.
Main function
Class
Control function
Protection function
Item
Torque control
Contents
Generate the torque by controlling the amount and the
direction of stator current according to the position of rotor
Over temperature If excess the restrictive temperature of inverter and motor,
limit
then limit the motor power
Main iteam
• Current control
• Rotor position and speed
detection
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limit the max motor power
according with inverter and motor
temperature
Failure detection
Cooperative control
Vehice driving
control
• Detection of problems related to the exernal inerface
• Fault detection in the inverter
• Detection of disorders
associated with inverter
• Fault detection of performance
related
• Inverter hardwere failure
detection
The communication with the another controller of necessary
information from the vehicle
• Demand torque, Battery
condition, EWP, and other
receive information
• Inverter status information
transmission
Vehicle Control System
Block diagram
Traction motor control
Inverter provides the available torque to VCU for calculating the necessary torque and develops the PWM signal to make the necessary
motor torque calculated by VCU.
Regenerative braking control
Inverter provides the available torque and the actual motor torque to VCU for calculating the necessary torque and develops the PWM signal
to make the necessary motor torque calculated by VCU.
Vehicle Control System
Description
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• High voltage (DC 360V) of the high voltage battery is converted low voltage (DC 12V) through the LDC for supplying power to electrical
components.
• Operation and operation mod of LDC are controlled by the vehicle control unit (VCU).
• The low voltage DC/DC converter is integrated into the EPCU.
System flow
Item
Specification
Input
High Voltage Battery (360V)
Output
Auxiliary Battery (12V)
Purpose
Auxiliary battery recharge and power supply to electric loads
Characteristics
Idle stop: Power supply is enabled
Temperature characteristics: Constant power
Item
Specification
Vehicle Control System
Specifications
▷ CMF45L-BCI
Capaticy [20HR/5HR] (AH)
45/36
Cold Cranking Amperage (A)
410 (SAE) /328 (EN)
Reserve Capacity (Min)
80
Vehicle Control System
Components
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1. Auxiliary 12V Battery
2. Battery mounting bracket
3. Battery tray
Vehicle Control System
Description
• The CMF(Closed Maintenance Free) battery is, as the name implies, totally maintenance free and has no removable battery cell caps.
• The CMF(Closed Maintenance Free) battery does not require water replenishment for the repair.
• The battery is completely sealed, except for small vent holes in the cover.
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Battery sensor
Battery sensor (A) is mounted on battery (-) terminal. It transmits battery voltage, current, temperature information to LDC. LDC controls
generating voltage by duty cycle based on these signals.
Electrical components power (12V) supply flow
• BMS ECU (Battery Management System Electronic Control Unit): Provide information (available battery power, state of charge)
• VCU (Vehicle Control Unit): Determine operation mod of the LDC according to battery status and vehicle status
• LDC (Low voltage DC/DC Converter): Supplies power to the vehicle electrical components after LDC is convert low voltage to high
voltage according to control of VCU.
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* APS: Accelerator pedal position sensor
Vehicle Control System
Removal
Battery & tray
1. Disconnect the battery terminals .
Tightening torque
(+): 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
(-): 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
2. Remove the battery after removing a battery mounting bracket (A).
Tightening torque :8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
3. Remove the battery tray (A) after loosening bolts.
Tightening torque :8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
Batterty sensor
1. Disconnect the battery negative (-) cable.
2. Disconnect the battery sensor connector (A).
3. Remove the battery negative (-) cable after removing the bolt (B).
Tightening torque
(-) terminal: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
(B): 26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)
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Installation
Battery & tray
1. Install in the reverse order of removal.
• When installing the battery, fix the mounting bracket on the tray correctly.
Batterty sensor
1. Install in the reverse order of removal.
• For the vehicle equipped with a battery sensor, be careful not to damage the battery sensor when the battery is replaced or
recharged.
1) When replacing the battery, it should be same one (type, capacity and brand) that is originally installed on your vehicle. If a
battery of a different type is replaced, the battery sensor may recognize the battery to be abnormal.
2) When installing the ground cable on the negative post of battery, tighten the clamp with specified torque. An excessive tightening
torque can damage the PCB internal circuit and the battery terminal .
3) When recharging the battery, ground the negative terminal of the booster battery to the vehicle body.
Adjustment
Battery Sensor Recalibration Procedure
After reconnecting the battery negative cable, AMS function does not operates until the system is stabilized, about 4 hours. If disconnecting
the negative (-) battery cable from the battery during repair work for the vehicle equipped with AMS function, Battery sensor recalibration
procedure should be performed after finishing the repair work.
1. Turn the Ignition switch ON and OFF.
2. Park the vehicle for about 4 hours with the hood and all doors closed.
Inspection
Vehicle parasitic current inspection
1. Turn the all electric devices OFF, and then turn the ignition switch OFF.
2. Close all doors except the engine hood, and then lock all doors.
(1) Disconnect the hood switch connector.
(2) Close the trunk lid.
(3) Close the doors or remove the door switches.
3. Wait a few minutes until the vehicle’s electrical systems go to sleep mode.
For an accurate measurement of a vehicle parasitic current, all electrical systems should go to sleep mode. (It takes at least one
hour or at most one day.) However, an approximate vehicle parasitic current can be measured after 10~20 minutes.
4. Connect an ammeter in series between the battery (-) terminal and the ground cable, and then disconnect the clamp from the battery (-)
terminal slowly.
• Be careful that the lead wires of an ammeter do not come off from the battery (-) terminal and the ground cable to prevent the
battery from being reset. In case the battery is reset, connect the battery cable again, and then start the engine or turn the
ignition switch ON for more than 10 sec. Repeat the procedure from No. 1.To prevent the battery from being reset during the
inspection,
1) Connect a jump cable between the battery (-) terminal and the ground cable.
2) Disconnect the ground cable from the battery (-) terminal.
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3) Connect an ammeter between the battery (-) terminal and the ground cable.
4) After disconnecting the jump cable, read the current value of the ammeter.
5. Read the current value of the ammeter.
A. If the parasitic current is over the limit value, search for abnormal circuit by removing a fuse one by one and checking the parasitic
current.
A. Reconnect the suspected parasitic current draw circuit fuse only and search for suspected unit by removing a component connected
with the circuit one by one until the parasitic draw drops below limit value.
Limit value (after 10~20 min.) :Below 50mA
Cleaning
1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.
Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the electrolyte. Heavy rubber gloves
(not the household type) should be wore when removing the battery.
4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary to clean the area with
a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe off with a cloth moistened with baking soda
and water.
5. Clean the top of the battery with the same solution as described above.
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed cables and broken
terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke near batteries being
charged or which have recently been charged. Do not break live circuit at the terminals of batteries being charged.A spark will occur
when the circuit is broken. Keep open flames away from battery.
Vehicle Control System
Troubleshooting
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Vehicle Control System
Description
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Main Features
Main Features
Drive Motor Control
Regenerative Brake Control
A/C Load Control
Electric Load Power Supply
Details
Calculates motor torque command with consideration to usable battery power, usable motor
torque, and driver demand (APS, Brake SW, Shift Lever)
• Calculates motor charge torque command for regenerative braking.
• Calculates regenerative brake force.
Sends final FATC allowed power by using the battery information and FATC requested power
data.
Determines LDC ON/OFF and operation mode based on the battery information and vehicle
status.
Cluster Display
Drive Power, Energy Flow, ECO Level, Power Down, Shift Lever Position, Service Lamp &
Ready Lamp ON Request
DTE (Distance to Empty)
• Indicates usable battery energy, and distance to empty based on prior drive pattern.
• If drive path is set by using AVN, DTE accuracy is improved by estimating the energy
consumption to destination.
Reserve/Remote Charge/A/C
Analog/digital signal processing and
diagnosis
• Remote control via Center/Smartphone through synchronization with TMU.
• Reservation function through operation time setting by driver.
APS, Brake Switch, Shift Lever, Airbag Deployment Signal processing and diagnosis
Vehicle Control System
Cruise Control
The cruise control system is engaged by the cruise "ON/OFF" main switch located on right of steering wheel column. The system has the
capability to cruise, coast, accelerate and resume speed.
It also has a safety interrupt, engaged upon depressing brake or shifting select lever.
The ECM is the control module for this system. The main components of cruise control system are mode control switches, transmission
range switch, brake switch, vehicle speed sensor, ECM and ETS motor that connect throttle body.
The ECM contains a low speed limit which will prevent system engagement below a minimum speed of 40km/h (25mph).
The operation of the controller is controlled by mode control switches located on steering wheel.
Transmission range switch and brake switch are provided to disengage the cruise control system. The switches are on brake pedal bracket
and transmission. When the brake pedal is depressed or select lever shifted, the cruise control system is electrically disengaged and the
throttle is returned to the idle position.
Cruise main switch (ON/OFF)
The cruise control system is engaged by pressing the cruise "ON/OFF" main switch. Pressing the cruise "ON/OFF" main switch again
releases throttle, clears cruise memory speed, and puts vehicle in a non-cruise mode.
Set/Coast switch (SET/–)
The "SET/–" switch located on right of steering wheel column has two functions.
The set function - Push the "SET/–" switch and release it at the desired speed. The SET indicator light in the instrument cluster will
illuminate. Release the accelerator pedal. The desired speed will automatically be maintained.
The coast function - Push the "SET/–" switch and hold it when the cruise control is on. The vehicle will gradually slow down. Release the
switch at the desired speed. The desired speed will be maintained.
Push the "SET/–" switch and release it quickly. The cruising speed will decrease by 2.0km/h (1.2mph) or 1.6km/h (1.0mph).
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Resume/Accel switch (RES/+)
The "RES/+" switch located on right of steering wheel column has two functions.
The resume function - If any method other than the cruise “ON/OFF” main switch was used to cancel cruising speed temporarily and the
system is still activated, the most recent set speed will automatically resume when the "RES/+" switch is pushed. It will not resume, however,
if the vehicle speed has dropped below approximately 40km/h (25mph).
The accel function - Push the "RES/+" switch and hold it when the cruise control is on. The vehicle will gradually accelerate. Release the
switch at the desired speed. The desired speed will be maintained.
Push the "RES/+" switch and release it quickly. The cruising speed will increase by 2.0km/h (1.2mph) or 1.6km/h (1.0mph).
Cancel switch (CANCEL)
The cruise control system is temporarily disengaged by pushing the "CANCEL" switch.
Cruise speed canceled by this switch can be recovered by pushing the "RES/+" switch.
Vehicle Control System
System Block Diagram
Component Parts And Function Outline
Component part
Vehicle-speed sensor, ESP/ABS Control Module
Function
Converts vehicle speed to pulse.
ECM
Receives signals from sensor and control switches.
Cruise control indicator
Illuminate when CRUISE main switch is ON (Built into cluster)
Cruise Control switches
Cancel switches
CRUISE switch
Switch for automatic speed control power supply.
Resume/Accel switch (RES +)
Set/Coast switch (RES -)
Controls automatic speed control functions by Resume/Accel switch
(Set/Coast switch)
Cancel switch
Sends cancel signals to ECM.
Brake-pedal switch
Transaxle range switch (A/T)
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ETC Motor
Regulates the throttle valve to the set opening by ECM.
* ETC Motor : Electronic Throttle Control Motor
Vehicle Control System
Trouble Symptom Charts
Trouble Symptom 1
Trouble Symptom 2
Trouble symptom
The set vehicle speed varies greatly upward
or downward
"Surging" (repeated alternating acceleration
and deceleration) occurs after setting
Probable cause
Remedy
Malfunction of the vehicle speed sensor circuit
Repair the vehicle speed sensor system, or
replace the part
Malfunction of ECM
Check input and output signals at ECM
Trouble Symptom 3
Trouble symptom
The CC system is not canceled when the
brake pedal is depressed
Probable cause
Remedy
Damaged or disconnected wiring of the brake Repair the harness or replace the brake pedal
pedal switch
switch
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Malfunction of the ECM signals
Check input and output signals at ECM
Trouble Symptom 4
Trouble symptom
The CC system is not canceled when the shift
lever is moved to the "N" position (It is
canceled, however, when the brake pedal is
depressed)
Probable cause
Damaged or disconnected wiring of inhibitor
switch input circuit
Improper adjustment of inhibitor switch
Malfunction of the ECM signals
Remedy
Repair the harness or repair or replace the
inhibitor switch
Check input and output signals at ECM
Trouble Symptom 5
Trouble symptom
Probable cause
Temporary damaged or disconnected wiring
Cannot decelerate (coast) by using the "SET/ of "SET/–" switch input circuit
–" switch
Malfunction of the ECM signals
Remedy
Repair the harness or replace the "SET/–"
switch
Check input and output signals at ECM
Trouble Symptom 6
Trouble symptom
Probable cause
Damaged or disconnected wiring, or short
Cannot accelerate or resume speed by using circuit, or "RES/+" switch input circuit
the "RES/+" switch
Malfunction of the ECM signals
Remedy
Repair the harness or replace the "RES/+"
switch
Check input and output signals at ECM
Trouble Symptom 7
Trouble symptom
Probable cause
Remedy
CC system can be set while driving at a
Repair the vehicle speed sensor system, or
vehicle speed of less than 40km/h (25mph), or Malfunction of the vehicle-speed sensor circuit replace the part
there is no automatic cancellation at that
Malfunction of the ECM signals
Check input and output signals at ECM
speed
Trouble Symptom 8
Trouble symptom
The cruise main switch indicator lamp does
not illuminate (But CC system is normal)
Vehicle Control System
Component Location
Probable cause
Remedy
Damaged or disconnected bulb of cruise main
switch indicator lamp
Repair the harness or replace the part.
Harness damaged or disconnected
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1. Audio switch (LH)
2. Cruise switch (RH)
Vehicle Control System
Circuit Diagram
Vehicle Control System
Removal
1. Disconnect the negative (-) battery terminal.
2. Remove the driver airbag module.
(Refer to the RT group)
3. Remove the steering wheel.
(Refer to the ST group - "Steering column & shaft")
4. Loosen the mounting screws from the rear steering wheel cover.
3. Bluetooth hands free switch
4. Trip switch
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5. Separate the upper steering wheel remote control switch (A) from the steering wheel.
6. Remove the upper steering wheel control switch (B) disconnecting the connector (A).
Installation
1. Install in the reverse order of removal.
Inspection
[Measuring Resistance]
1. Disconnect the cruise control switch connector from the control switch.
2. Measure resistance between terminals on the control switch when each function switch is ON (switch is depressed).
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Function switch
Terminal
Resistance
[kΩ ± 5%]
CANCEL
2-4
0.18
SET–
2-4
0.33
RES+
2-4
0.55
CRUISE
2-4
0.88
3. If not within specification, replace switch.
[Measuring Voltage]
1. Connect the cruise control switch connector to the control switch.
2. Measure voltage between terminals on the harness side connector when each function switch is ON (switch is depressed).
Function switch
Terminal
Voltage (V)
CANCEL
2-4
0.63 ~ 0.97
SET–
2-4
1.03 ~ 1.37
RES+
2-4
1.58 ~ 2.02
CRUISE
2-4
2.08 ~ 2.52
3. If not within specification, replace switch.