1. Model OutlineEngineChassisBodyBody Electrical 1 Contents Click a Section Tab

2. Model OutlineEngineChassisBodyBody Electrical 2 Manual Transaxle Automatic Transaxle Front Suspension Front Axle Brake Brake Control System Steering

3. Model OutlineEngineChassisBodyBody Electrical Manual Transaxle Transaxle control cable –Select cable with cable length adjustment mechanism TMC and TMT Model Adjustment Mechanism Shift Lever Shift Cable Select Cable Transaxle

4. Model OutlineEngineChassisBodyBody Electrical 4 Service Point (Manual Transaxle) Select Cable –Adjustment for TMC and TMT model Select Cable 1 1 3 3 4 4 5 5 2 2 Lock Piece Adjuster Case Cover

5. Model OutlineEngineChassisBodyBody Electrical Automatic Transaxle Transaxle Control Cable –Cable length adjustment mechanism Adjustment Mechanism Shift Lever Control Cable Transaxle

6. Model OutlineEngineChassisBodyBody Electrical 6 Service Point (Automatic Transaxle) Transaxle Control Cable –Adjustment Select Cable 2 2 4 4 5 5 6 6 3 3 Lock Piece Adjuster Case Cover 1 1 Shift to N range

7. Model OutlineEngineChassisBodyBody Electrical Automatic Transaxle U340E Automatic Transaxle –ATF type is changed to WS from T-IV for fuel economy by reducing its viscosity ATF Temp.High ATF Viscosity Thick T-IV WS

8. Model OutlineEngineChassisBodyBody Electrical Automatic Transaxle U340E Automatic Transaxle –ATF WS is not interchangeable with other type of ATF (e.g. T-IV)

9. Model OutlineEngineChassisBodyBody Electrical Automatic Transaxle U340E Automatic Transaxle –Color of Level Gauge is change from Orange to Black

10. Model OutlineEngineChassisBodyBody Electrical Front Suspension Upper Support –Installed by 1 nut Suspension Support No.2 Dust Cover Body Front Shock Absorber Assembly Nut

11. Model OutlineEngineChassisBodyBody Electrical 11 Reference (Front Suspension) Upper Support Shock Absorber Rod Suspension Support Dust Cover Coil Spring Body Nut Suspension Support No.2 Ball Bearing Insulator Upper Spring Seat Upper Front Shock Absorber Nut Bound Stopper

12. Model OutlineEngineChassisBodyBody Electrical Front Suspension Front Shock Absorbers –A multi-leaf type linear control valve Damping Force Lo Speed Medium to high Speed Piston Speed Conventional New Extension Compression

13. Model OutlineEngineChassisBodyBody Electrical Front Axle Axle Hub Bearing –Built-in speed sensor rotor Brake Dust Cover Steering Knuckle Snap Ring Axle Hub Speed Sensor Rotor Axle Hub Bearing

14. Model OutlineEngineChassisBodyBody Electrical 14 Service Point (Front Axle) Axle Hub Bearing –When install the axle hub bearing, set the speed sensor rotor surface to vehicle inside InsideOutside Speed Sensor Rotor

15. Model OutlineEngineChassisBodyBody Electrical Brake Dust Cover (non-reusable) Steering Knuckle Snap Ring Axle Hub Axle Hub Bearing Front Axle Brake Dust Cover –Press-in type brake dust cover is used (TMC and TMT model only) Press-in

16. Model OutlineEngineChassisBodyBody Electrical 16 Service Point (Front Axle) Brake Dust Cover –Installation procedure (1/2) 2. Press-in the dust cover 1. Set the new dust cover SST 19.8 mm (0.78 in.)

17. Model OutlineEngineChassisBodyBody Electrical 17 Service Point (Front Axle) Brake Dust Cover –Installation procedure (2/2) 3. Fix the 3 point

18. Model OutlineEngineChassisBodyBody Electrical Brake Rear Disc Brake –Built-in parking brake is used for rear disc bake model TMC and TMT Model Built-in Parking Brake

19. Model OutlineEngineChassisBodyBody Electrical Brake Rear Disc Brake –Construction Pad Piston Nut Sleeve Operation Lever Push Rod Check Ball Input Shaft

20. Model OutlineEngineChassisBodyBody Electrical Brake Rear Disc Brake –Parking brake operation PKB OFF PKB ON Depth of the check ball groove changed

21. Model OutlineEngineChassisBodyBody Electrical Brake Rear Disc Brake –Adjustment operation Clearance After braking Turned & Moved Pad is worn At Braking

22. Model OutlineEngineChassisBodyBody Electrical 22 Service Point (Brake) Rear Disc Brake –Use the SST when … remove or install the brake piston adjust the protrusion amount of the brake piston SST

23. Model OutlineEngineChassisBodyBody Electrical 23 Service Point (Brake) Rear Disc Brake (TMC and TMT Model only) –Align the piston direction when the installation Installation direction of the brake piston 90° Protrusion portion

24. Model OutlineEngineChassisBodyBody Electrical 24 Service Point (Brake) Rear Disc Brake –Parking brake lever travel adjustment Confirm the clearance between operation lever and stopper (at the parking brake released) Confirm the clearance between operation lever and stopper (at the parking brake released) Check and adjust the Lever Travel TMC and TMT Model Standard: 0 – 0.5 mm (0 – 0.02 in.) - Click the illustration to enlarge view -

25. Model OutlineEngineChassisBodyBody Electrical Brake Control System Mechanical Brake Assist Without BA during emergency brakingWith BA during emergency braking Control Valve “Close” Constant Pressure Chamber Variable Pressure Chamber PUSH Power Piston Operation Rod Air Valve “Wide Open” Slide Valve Slide Valve Hook

26. Model OutlineEngineChassisBodyBody Electrical Brake Control System Speed Sensor –Type of speed sensor has been changed from passive type to active type Active Type (Semiconductor) Passive Type (Magnetic pick-up) Magnet Coil Yoke Rotor Magnetic Rotor MRE

27. Model OutlineEngineChassisBodyBody Electrical Brake Control System Speed Sensor –MRE internal operation Magnetic Rotor MRE Output Comparator Output Output 2 4 1 0 12V 0V Constant Voltage Circuit Comparator Output + - MRE +B 1 2 3 4

28. Model OutlineEngineChassisBodyBody Electrical Brake Control System Speed Sensor –Sensor output FL+ FL- Power supply (12V) MRE

29. Model OutlineEngineChassisBodyBody Electrical 29 Service Point (Brake Control System) Speed Sensor –Inspection procedure Skid Control ECU FL+ FL- GND 12V FL- to GND 100  Low SpeedHigh Speed MRE 1.4V 0.7V

30. Model OutlineEngineChassisBodyBody Electrical Service Point (Brake System) Accessing the brake fluid reservoir 1 2 3

31. Model OutlineEngineChassisBodyBody Electrical Steering System Diagram DLC3 Engine ECU (ECM) Meter ECU Skid Control ECU EPS ECU Warning LightVehicle Speed Signal Engine Speed Signal DTC Torque Sensors DC Motor Reduction Mechanism Temp. Sensor Boost Converter CAN

32. Model OutlineEngineChassisBodyBody Electrical Steering Steering Column and DC Motor –DC motor with resolver type rotation angle sensor which reduces motor speed via worm gear and transmits it to the column shaft Motor Wheel Gear Output Shaft Input Shaft Torsion Bar Torque Sensor Column Shaft [Motor] Rotor Stator Worm Gear Column Shaft Wheel Gear

33. Model OutlineEngineChassisBodyBody Electrical Steering Torque Sensor –Torque sensor using detection ring 1 and 2 mounted on the input shaft, and detection ring 3 mounted on the output shaft Motor Output Shaft Input Shaft Torsion Bar Torque Sensor Column Shaft Wheel Gear [Torque Sensor]

34. Model OutlineEngineChassisBodyBody Electrical Steering Torque Sensor –Output volatge

35. Model OutlineEngineChassisBodyBody Electrical Steering EPS Operation –There are the following functions in assist control ItemFunction Basic Control Calculates the assist current from the steering torque value and the vehicle speed, and actuates the motor Inertia Compensation Control Improves the starting movement of the motor when the driver starts to turn the steering wheel Recovery Control During the short interval between the time the driver fully turns the steering wheel and the wheels try to recover, this control assists the recovery force Damper Control Regulates the amount of assist when the driver turns the steering wheel while driving at high speeds, thus damping the changes in the yaw rate of the vehicle body System Overheat Protection Control Estimates the motor temp. based on the amperage and the current duration. If the temp. exceeds the standard, it limits the amperage to prevent the motor from overheating

36. Model OutlineEngineChassisBodyBody Electrical Steering Diagnosis and Fail-safe –When malfunction occurs in EPS system, EPS ECU controls following control; Turns on P/S warning light and fail-safe operation DTC No.Detection ItemP/S C1511 / 11 Torque sensor malfunctionIlluminate C1512 / 12 C1513 / 13 C1514 / 14Torque sensor power supply abnormalIlluminate C1515 / 15Torque sensor zero point adjustment undoneIlluminate C1516 / 16Torque sensor zero point adjustment incompleteIlluminate C1517 / 17Torque hold abnormalIlluminate C1524 / 24Motor circuit malfunctionIlluminate

37. Model OutlineEngineChassisBodyBody Electrical Steering Diagnosis and Fail-safe DTC No.Detection ItemP/S C1531 / 31 ECU malfunctionIlluminate C1532 / 32 C1533 / 33 ECU malfunctionIlluminate C1534 / 34 C1551 / 51IG power source voltage malfunctionIlluminate C1552 / 52PIG power supply voltage malfunctionIlluminate C1554 / 54Power supply relay failureIlluminate C1555 / 55Motor relay failureIlluminate C1581 / 81Assist map number un-writingIlluminate U0073 / 91Control module communication bus offIlluminate U0105 / 92Lost communication with powertrain ECU  U0121 / 93 Lost communication with anti-lock brake system (ABS) control module Illuminate

38. Model OutlineEngineChassisBodyBody Electrical Steering Diagnosis and Fail-safe Fail-safe OperationItems Prohibits steering assist control Malfunction of torque sensor Motor short Motor overcurrent Malfunction of EPS ECU Limits steering assist control Until temperature falls Motor Overheating ECU overheating Until normal signals are received Malfunction of vehicle speed signal Malfunction of engine speed signal Until normal conditionMalfunction of power supply voltage

39. Model OutlineEngineChassisBodyBody Electrical Steering Initialization and Calibration –Perform the initialization and calibration of EPS system in the following cases Steering Wheel Steering column assy Steering gear assy EPS ECU Remove, install or replacing Replace the new one Using Intelligent Tester-II Using the SST NOTE: These operation cannot be performed when the DTCs are outputted except C1515 / C1525

40. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II Select Chassis  EPS  Utility  Torque Sensor Adjustment Select Chassis  EPS  Utility  Torque Sensor Adjustment Click!

41. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

42. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

43. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

44. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

45. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

46. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

47. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II 10

48. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II 10

49. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

50. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

51. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II 10

52. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

53. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the intelligent tester-II

54. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –If DTCs are outputted except C1515 / C1525

55. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the SST (09083-18040) 1. Initialization of EPS ECU CG 1. Connect terminals Tc,Ts and CG and turn the ignition switch to ON TsTc 2. Disconnect and connect terminal Tc 20 times within 20sec. 3. Confirm the P/S warning light indicates 4. Turn the ignition switch to OFF P/S

56. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the SST (09083-18040) 2. Calibration of motor rotation angle sensor CG 1. Connect terminals Ts and CG and turn the ignition switch to ON Ts 2. Turn the steering 45 degree or more (both side) N

57. Model OutlineEngineChassisBodyBody Electrical Service Point (Steering) Initialization and Calibration –Using the SST (09083-18040) 3. Calibration of torque sensor CG 1. Connect terminal Tc after calibration of motor rotation angle sensor Ts 2. Confirm the P/S warning light blinks 3. Disconnect SST and turn the ignition switch to OFF P/S