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JM - Introduction

JM (TUCSON) Service Training Guide

Published by Chonan Technical Service Training Center

Chonan Technical Service Training Center

JM - Introduction

FOREWORD
This service-training booklet has been prepared for service technicians of authorized Hyundai distributor to familiarize them with JM (TUCSON). It is our intention to increase the level of skill and knowledge of service personnel to enable effective and efficient problem diagnosis and repair.

February, 2004 Printed in Korea Published by Chonan Technical Service Training Center

copyright by Hyundai Motor Company All right reserved. Chonan Technical Service Training Center http://training.hmc.co.kr training@hmc.co.kr

Chonan Technical Service Training Center

JM - Introduction

Contents

Chonan Technical Service Training Center

JM - Introduction

1. Introduction
1.1 General
JM car was developed as a concept of small sized SUV (Sports Utility Vehicle) based on the same platform with XD Elantra. Its size is smaller than current SM (Santa Fe) but the exterior styling is a little bit similar with it. The vehicle name of JM is a TUCSON. It is the city name of USA in Arizona State. This city is located in the desert area and has a Spanish culture. Also the old western styled building and the most modern tradition coexists together. This name represents the crossover image and the dynamic feeling of JM car as a SUV. - SUV unique features

Roof Rack Privacy Glass (Rear Door + QTR + Backlite Glass)

195mm

Underbody Skid Plate

Wheel Arch Molding Flip-up Tail Gate Glass Side Garnish Electronic controlled Large Tire & Wheel 215/16 inch 235/16 inch (Option) 4 Chonan Technical Service Training Center 4WD Function

JM - Introduction
- Vehicle concept All New Sophisticated Concept

SUV

SEDAN

JM

MPV

Market Needs & Trend

Line-up & Brand Image

Car

Ride & Handling - Based on XD Platform Eng, TM, Steering, Suspension

SUV

Exterior Styling - Simple but Strong - Large Tire & Ground Clearance Torque on Demand Type 4WD - Highly Advanced 4WD System

MPV

Space Utility - Flexible Seat Mechanism - Extra-Wide Cargo Room

Chonan Technical Service Training Center

JM - Introduction

Mild Vitara M-Class Explorer Off-Rood X5 On-Road

JM

HP

Freelander

SM

RAV4

CR-V Wrangler Rugged

- Interior Crash Pad & Storage

Lower Crash Pad Tray Tray under

Cup Holder

Bottle Holder & Map Pocket Deluxe console 6

Tray under Fascia Panel

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JM - Introduction
Luggage Area
Same Plastics Washable Luggage Floor Front - Walk-Through Rear - Full Flat Luggage Net Luggage Tray - Seat Armrest (Driver) - Center Armrest - Seat Under tray (Passenger) - Forward Folding and Dive to Floor for - Seatback Folding to Table Form (Passenger) luggage Area Seatback Full-Flat Height Adjustable Walk-Through Export Product

Rear Seats Folding & Dive

Rear Center Armrest

- Comparison
Items

to The Floor Hyundai JM Santa Fe


Differe nce

Toyota RAV4

Honda CR-V

Exterior

( - )

Overall Length Overall Width Overall Height Wheel Base Wheel Tread Tire

4,325 1,795 1,680 2,630 1,540 215 / 65 R16 235 / 60 R16

-175 -25 +5 +10 0

4,500 1,820 1,675 2,620 1,540 225 / 70 R16

4,221 1,735 1,679 2,489 1,505 215 / 70 R16

4,536 1,783 1,681 2,619 1,535 205 / 70 R15

- Safety

- Meet All Regulation - Rear Center 3 Point Seat Belt & Headrest - ABS & TCS - ESP - Dual Air Bags - Side Air Bags and Air Curtain
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- Convenience

- Power Window & Central Door Lock - Keyless Entry - Electric Sunroof & Overhead Console - Power Outlet (2EA) - Trip Computer - Auto Light Control - Full Auto Air Con - Air Quality Control System - Various Audio (Radio, Cassette, CD, MP3) - Product value * Hiden In Belt type of door trim was applied.

Exposed In Belt

8 Hiden

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JM - Introduction

For better exterior view, lower weight and cost. * Non-housing type outside door handle was applied. For better exterior view and lower cost.

Housing type

Non-housing type

* Flip-up type tailgate Same system in Santa Fe.

JM: Hidden wire 9

SM: Exposed wire for glass heating Chonan Technical Service Training Center

JM - Introduction

* De-icer wiper

* Rear seat

Reclining

Fold & Dive

* Mounting

FRT ROLL

ENG MTG.

TM MTG

RR ROLL

* Propeller shaft For lower NVH.


Center bearing rubber

Rubber Coupling

Bending absorber (inside of tube) Universal joint

* Hub bearing For lower noise. : Dust cover added. , : Reduced gap to prevent the inlet of foreign materials. Increased bearing capacity: (XD Carry over SM Carry over)

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JM - Introduction

* Electrical contact connector To improve the exterior view of the flip-up type tailgate wire, the electrical contact type connector was applied instead of the curl wire.

* 4-Ring body structure for higher strength


Ring #1

Ring #4

Ring #3 Ring #2

* Double box structure for 4WD device


Propeller shaft Inside

Outside

4WD P/Shaft

* Door beam Layout The optimized door beam layout for the enhanced strength against the side impact.

Front

Rear

* Swollen face on the floor To absorb the vibration generated from the floor,
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the swollen face was applied on the floor.

* One more hood-fixing guide

Two hood-fixing guides for easier repair on engine room area.

* EGR cooler (D-2.0 C/Rail engine only)


Coolant OUT EGR Cooler

EGR valve

Coolant IN

Cooled exhaust gas

Exhaust gas (Hot) Exhaust manifold

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1.2 Technical Highlights


- Engine

2.0 I4 GSL Engine - 145 ps/6,000 rpm - 19.0 kgm/4,000 rpm

CR-V - 2.0 Gas (150 ps) - No DSL Engine

D 2.0 DSL Engine (Europe) - 111 ps/4,000 rpm - 25.0 kgm/2,000 rpm

RAV4 - 2.0 Gas (150 ps) - 2.0 DSL (116 ps) - No Premium Engine

2.7 V6 GSL Engine - 175 ps/6,000 rpm - 24.7 kgm/4,000 rpm

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JM - Introduction

- Manual Transaxle 5-Speed Manual Transaxle Drive train Variant


2WD MT -2.0 I4 Gas -2.7 V6 Gas D-2.0 DSL M5GF1 M5GF1 F4A42 AT F4A42 MT M5GF1 M5GF1 4WD AT F4A42 F4A42

M5GF1 model:
nd

3 friction faces Sleeve

2 gear

1 gear

st

Triple synchronizer

- Applied on EF, FO car - Triple synchronizer cone was adopted on the 1st,2nd synchronier gear to improve shift feeling and reduce shifting force. - Keyless type:
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JM - Introduction
Key and type spring were replaced with the - Clutch: Hydraulic Push type - SMF (Single Mass Flywheel) was applied.

- 4WD system 4WD Locking Button on Fascia Panel

Front Axle Transfer Case

Constant 2WD/4WD or Auto Control - 2WD: Front Wheel Drive - 4WD: Electronically Controlled All Wheel Drive

ECM

Rear Axle

Transfer case

Rear axle & Coupling

- Normal driving with constant speed: Driven with FF2WD.


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JM - Introduction
- Sudden vehicle starting, low friction road driving: Driven with 4WD automatically by ECM control. - Better fuel consumption and faster response than mechanical type. - Automatic Transaxle Applied model: HIVEC F4A42
P Cable end Key lock cable

Shift lock cable

Washer Spring

F4A42 for 4WD transfer

The shift lock and key lock cable were applied. (Only N/A, Aust., Taiwan, Japan) TCM Location * For LHD
TCM : -2.7 / D-2.0

* For RHD

ECM (PCM)

ECM (PCM) ECU(PC

TCM: -2.7 / D-2.0

RH Side inner panel

LH Side inner panel

* Sports mode 4-speed front driving * A/T relay DTC code was changed.
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JM - Introduction
- Old: P1723 (A/T relay open or short) - New: P0885 (A/T relay open or short) - Application: From JM vehicle - Objective: To satisfy the renewed regulation of North America. * It is planned to adopt F4A51 in D-2.0 VGT. - ESP System
HECU Wheel speed sensor Steering angle sensor Yaw rate sensor & Lateral G sensor

Mando MGH-25 ESP HECU 2WD ESP Wheel speed sensor ACTIVE 4WD ESP ACTIVE Remarks 2WD/4WD FRT: Same RR: Diff. ESP H/UNIT Pressure sensor Steering angle sensor Yaw rate sensor Lateral G sensor ESP 4WD O O O X ESP 2WD O O O O Same shape Master cylinder -

* Objectives: - For more stable handling performance - To prevent the oversteering and understeering effect

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JM - Introduction

- SRS System

Side body deformation

Floor deformation

* Depowered airbag system (Except North America) ACU (Airbag Control Unit): Bosch, AB8E Model - DAB, PAB, SAB, CAB - Single threshold without buckle switch - TRW (Germany)s CAB (Curtain Airbag) was applied to satisfy the regulation (Euro NCAP Car-to-Pole) - FIS (Frontal impact sensor) was applied. - PPD (Passenger presence detection) sensor removed. - CAB and SAB are deployed together always. * Advanced airbag system (North America only) - Delphi (USA) system to satisfy the new regulation of FMVSS 208 (USA)
PAB Module (2stage) PPD sensor Telltale lamp
PASSENGER AIRBAG OFF

Pretensioner sensor Seat track position sensor

Front impact sensor

18 DAB Module

Chonan Technical Service Training Center Buckle switch

JM - Introduction

- Body Electrical * Trip computer : DTE (Distance to empty), Average fuel consumption Odometer : Trip computer switch is located on the cluster housing.

* 20pin diagnosis connector in engine room


A B C E F D G H I J K L M N O P Q R S T

ECM

Immo. Control module OBD (7)

TCM

20 pin (K) 20 pin (O)

Terminal A B C D E F G H Body K-Line Chassis K-Line (Factory air bleeding) B+ (HMC only) B+ K L M N O P Q 19 R P/T K-Line

Terminal

MELCO TCM Reprogramming power IG Switch (Factory air bleeding) MELCO TCM Reprogramming Comm. - Service Training Center Chonan Technical GND

JM - Introduction

* RCT connector was removed and this 20 pin connector is used for TCM reprogramming. - Immobilizer system * D-2.0 C/Rail: Bosch SMARTA

- Operating voltage range: DC 6 ~ 16V - Operating temperature range: -40 ~+85 - Storage temperature range: -40 ~+85 - Current consumption: 100mA(min) 200mA(max) - Radio Frequency: 125kHz * Delta 2.7, Beta 2.0: Stand-alone

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JM - Introduction

- Operating voltage range: DC 8 ~ 16V - Operating temperature range: -40 ~+80 - Storage temperature range: -40 ~+85 - Current consumption: 20mA(typ) 500mA(max) - Frequency (Data transmitting): 134.2 kHz - Suspension * Front: Macpherson with coil spring - The improved design of lower arm was applied to reduce the shimmy noise. - The increased cross section of the suspension member enables the reduced idle booming noise. - Gas type shock absorber is applied as a standard. - Increased caster angle comparing SM (Santa Fe) to give better performance while direct forward driving. (SM: 2.5 * Rear: Dual link
Solid type Bush type

JM: 3.5)

- The bushing mounting was applied on the rear cross member.

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4WD Chonan Technical Service Training Center

JM - Introduction

- More enhanced design than XD was applied to improve the driving and steering feeling. - Reduced NVH. - Gas type shock absorber is applied as a standard.

1.2 Specifications

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JM - Introduction

1.3 Dimension

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JM - Introduction

Items Overall Length (mm) Overall Width (mm) Overall Height (mm) Wheel Base (mm) Tread (mm) Interior Length (mm) Interior Width (mm) Interior Height (mm) Ground Clearance (mm) FRT RR

Model

(All Area) 4,325 1,795 (1,830: with Side garnish) 1,680 (1,730: with Roof rack) 2,630 1,540 1,540 1,800 1,485 1,215 195

Measuring at

Sub frame

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JM - Introduction

1.4 Performance
- A/T

- M/T

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JM - Introduction

1.5 Offroad Specifications


Maximum load capacity of roof rack: 75kg

Breakover Approach angle 28.2


o

Front axle Clearance 200mm

Running Clearance 195mm

Angle 19
o

Rear axle Clearance 200mm

Departure angle 31.9


o

Climing angle: 39-41% (DSL, M/T, GVW, Starts from stationery condition)

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