Revue Technique Hyndai I10

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Engine
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PA - ENGINE 2
Application
Engine T/M Area
Volume Performance
Model [cc] [PS/kgf.m]
M/T A/T India Europe General
ε-1.1 1,086 64/9.9 M5EF2 A4CF0 ● ● ●
U-1.1 1,120 75/15.5 M5CF1 - - ● -
Epsilon 1.1L engine is already used for Santro(Atoz)

Kappa 1.2L engine, which is newly developed, will be applied in 2008.
Common Rail U-1.1L engine is only for EU market with manual transaxle.
Common Rail U-1.1L engine has 3 cylinders
Epsilon Engine
PA - ENGINE 4
Epsilon engine Engine ε-1.1

Displacement
1086
(cc)
Max. Power
64 / 5,500
(PS / RPM)
Max. Torque
9.8 / 2,800
(kgf·m / RPM)
• SOHC In-line 4 cylinders (12 valves)

• One Timing Belt
• DLI
Feature • BOSCH PCM
• Return-less fuel system
• ROSA type ISA
PA - ENGINE 5
Tightening Torque
-When cold : 60 ~ 70 Nm
-When hot : 70 ~ 75 Nm
Traditional torque method is used. To keep proper installation, mentioned

torque should be tightened with right procedure.
No.1’s
TDC
6
PA - ENGINE
■ Adjustment Specification
Rocker Arm
PA - ENGINE 7
Camshaft
■ Target Wheel
Be sure to remove camshaft from front side to rear side(fly wheel side).
PA - ENGINE 8
Piston
■ Upside Mark
Top ring and second ring have unique up side mark. Be sure to keep this mark
when you assemble piston ring to piston.
To assemble piston pin to piston SST(09324-33001) is needed.
9
PA - ENGINE
Timing
PA - ENGINE 10
Inlet Cooling System
Thermostat opening temperature is 82℃℃.

When it fully opens, it becomes 95℃
℃.
PA - ENGINE 11
Oil Pump and Oil Pressure Switch
At engine idle condition after warm up, normally

oil pressure reaches 147kpa(1.5kg/㎠)
Oil pressure switch is screwed near engine oil

filter. When the oil pressure goes down less
than 0.5kg/㎠, oil pressure warning lamp turns
on.
PA - ENGINE 12
Return Less Fuel System (RLFS)

Damper
D/Pipe
Injector
Resistance measurement
15.9
Inspection by test lamp Sound inspection

13
PA - ENGINE
Fuel Pump
PA - ENGINE 14
Ignition Coil and Spark Plug
Item Specification
Type Mold Dual Coil
Ignition Coil Primary Ω±10%

0.82Ω
Resistance
Secondary Ω±10%
15.5KΩ
PA - ENGINE 15
Input & Output
For European Market
10. WHEEL SPEED

SENSOR
For General Market

16
PA - ENGINE
Bosch M7.9.8
PA - ENGINE 17
T_MAP Sensor
Intake air temperature sensor is integrated with T_MAP sensor. It produces 0.3 ~ 4.8
voltage range as signal.
At ignition on condition, it shows 3.8 ~ 4.2 V which is converted to atmospheric pressure.

PA - ENGINE 18
IAT Sensor
When IAT fault is detected, current data shows -40℃ an a default

value.
Checking
Temperature Current Data Remarks
Condition
0℃ 4.0 ~ 4.4V
20℃ 3.3 ~ 3.7V
IG On NTC type
40℃ 2.5 ~ 2.9V
80℃ 1.0 ~ 1.4V
PA - ENGINE 19
TP Sensor (Lever type)
TPS
It’s better check TPS waveform with MAP
signal’s together. Both signals are similar and
MAP
signal trend has to be compared together.
PA - ENGINE 20
ECT Sensor
This sensor has 4 terminals. 2 are for ECT sensor. These two terminals are gold coated.
Another 2 are for engine temperature indicator in cluster.
Checking
Temperature Current Data Resistance (KΩ)
Condition
0℃ 4.27±0.3V 5.18 ~ 6.60
20℃ 3.44 ±0.3V 2.27 ~ 2.73
IG On
40℃ 2.72±0.3V 1.059 ~ 1.281
80℃ 1.25±0.3V 0.298 ~ 0.322
PA - ENGINE 21
CKP Sensor
Hall IC type CKP sensor is used. ECM

No. 15 is used for sensor signal.
Reference Point Missing Tooth
Unlike other general target wheel which
is composed with 60 teeth including 2
missing teeth, it has 30 teeth with 2
missing. Except tis tooth unit, all logical
processing in ECM is the same
PA - ENGINE 22
CMP Sensor
CMP sensor is also used from Hall IC.
It distinguishes the cylinder No. by

comparing with CKP sensor.
It is located near ignition coil. Camshaft

target wheel shape is as shown on the
picture.
[CMP with CKP Sensor Waveform]

PA - ENGINE 23
Oxygen Sensor
Rear or Down Stream

Oxygen Sensor
Front or Up Stream
Oxygen Sensor
Zirconia type oxygen sensor is used.

The Zirconia oxygen sensor generates a small voltage depending on the exhaust gas
condition.
The normal voltage range is 0.2 ~ 0.8 volts. 0.2 volts indicates a lean mixture and a
voltage of 0.8v indicates a richer mixture.
PA - ENGINE 24
Knock Sensor
Engine knock control is used to constrain the knocking.

Knock sensor detects knocking generated in engine and
retard ignition timing.
The knock sensor is installed at between No2. and No.3
cylinder. Like other piezo type sensors, this is made by piezo
material. Tightening torque is 20±5Nm.
• Maximum Retard Limit : 12˚
• When knocking is detected : Initially retard 3˚

and increase step by step with 0.75˚
PA - ENGINE 25
Wheel Speed Sensor
The main role of wheel speed sensor is detecting the rough load
condition which allows misfire monitoring inhibition (EOBD:Euro3/Euro4).
When the vehicle is running on rough load condition, the CKP angular
speed is affected from this road condition. It can signal to ECM as a
misfiring. In this case wheel speed sensor detects this kind of rough
load condition and order ECM not to consider this situation as a
misfiring.
M/T Input Variable ECU PIN NO.

With ABS ABS Signal K 64
With EOBD K 79, K 58
Without ABS Wheel Speed Sensor
(K 64 open)
With ABS K 64
Without EOBD Vehicle Speed Sensor
Without ABS K 64
AT Input Variable PCM PIN NO.
With ABS ABS Signal K 20
With EOBD
Without ABS Wheel Speed Sensor A 60, A 45
With ABS K 20
Without EOBD From TCM
Without ABS K 20
PA - ENGINE 26
Vehicle Speed Sensor
- Vehicle speed sensor is applied on MT only.
- In the case of AT, the vehicle speed sensor is eliminated.

Instead, ECM receives a corresponding vehicle speed from others.
(refer to the table below)
T/M Type Vehicle speed from ECU PIN NO.

With ABS ABS unit K64
With EOBD K79, K58
Without ABS Wheel Speed Sensor
MT (K 64 open)
With ABS
Without EOBD Vehicle Speed Sensor K64
Without ABS
With ABS ABS unit K20
With EOBD
Without ABS Wheel Speed Sensor K60, K45
AT
With ABS
Without EOBD From TCM K20(from A49)
Without ABS
PA - ENGINE 27
ISA (Idle Speed Actuator)

Coil assembly Drive unit
Housing
O-Ring
Axis
Stopper
Maintaining
Cushion
Valve screw
Magnet ring Ball
bearing
1. The ISA controls the proper intake air mass in every engine
operating conditions.
2. The ECU controls the ISA (double coil of open/close) with
frequency of 250Hz.
3. The ISA duty is determined by basic map and compensation
of ATS, WTS, altitude and A/CON compressed load etc.
PA - ENGINE 28
PCSV
For Evaporative gas monitoring.
PCSV is installed between the canister and the intake manifold, it

delivers or shuts the vapor gas to intake manifold, which is stored in
the canister. The ECM controls the purge control solenoid valve.
Common Rail U-Engine

PA - ENGINE 30
U engine
Engine U - 1.1 VGT
Displacement
1120
(cc)
Max. Power
75 / 4000
(PS / RPM)
Max. Torque
15.5 / 2000
(kgf·m / RPM)
• VGT Turbo Charger

• Timing Chain
• Electrical EGR & EGR cooler
• Lambda Sensor
Feature
• Throttle flap
• Serpentine belt
• Bed Plate
• In-line 3 cylinders
PA - ENGINE 31
System Overview
E.G.R cooler
Throttle flap
Electrical E.G.R
CRDi system
λ sensor
EURO-4: 1600bar
VGT
Serpentine belt
DOC (Diesel
Oxidation Catalyst)
HLA
4 valve DOHC Timing chain

PA - ENGINE 32
Timing System DOHC 4 Valve
Timing Chain
VALVE operating type:
- END PIVOT ROLLER SWING ARM
CAM operating type : 2 Chains
Hollow camshaft
Balance shaft Balance shaft is operated by gear

-> for reducing vibration
33
Balance Shaft
Timing Mark
PA - ENGINE
Balance Shaft
PA - ENGINE 34
Intake / Exhaust manifold

Electrical EGR Valve
VGT - Valve type : linear solenoid type
- Control voltage : 13.5V (Duty control)
Intake
- Coil resistance : 7.3 ~ 8.3 Ω (at 20℃)
EGR COOLER
Vane - Coolant cooling type
- Reduced intake air temperature
and increased intake air
To cylinder
Exhaust → Reduced NOx and PM
From cylinder WCC (Warm-up Catalytic Converter)
Lambda sensor
High Speed Low Speed

E / EGR Valve EGR cooler
PA - ENGINE 35
Fuel system – location / component

Component
Injector - High Pressure Pump
- Common Rail
- Injector
Cylinder
C/ Rail Head
High
pressure
Cylinder
pump
Block
Max. Pressure : 1600 bar

Duel pressure control (2 Governor control) : FPV + RPV
※ FRV : Fuel Pressure regulator Valve , RPV : Rail Pressure regulator Valve
PA - ENGINE 36
Fuel system – High Pressure Pump / Common Rail
High Pressure Pump Common Rail

- Type : CP1H - Allowed pressure : 1,600 bar
- Max. Pressure : 1600 bar
- Rail Pressure Sensor
: Max. Measurement : 1,800 bar
- Applied RPV
- Throttle
: Reduced fluctuation of fuel pressure
FPV
to injector
(Fuel
Pressure
regulator Throttle
Valve)
High
Pressure
Plunger
RPV Rail Pressure Sensor
(Rail Pressure
regulator Valve)
PA - ENGINE 37
Fuel system – Injector
Injector
- compensates fuel amount
: Applied IQA (Injector Quantity Adjustment) code for compensating fuel amount of each injectors
- Type : CRI2.2
- Max. Pressure : 1600 bar Controlled
by ECM
Ampere for solenoid control
Lift of armature
H/pressure
Fuel pressure of injector inside fuel
Injection pattern
PA - ENGINE 38
Current Data
Idle condition 1500 rpm 3000 rpm
Conditions
-No Electrical Load
-Neutral (Manual Transaxle)
-No DTC
PA - ENGINE 39
Current Data
Conditions
-No Electrical Load
-No DTC
PA - ENGINE 40
Current Data
Conditions
-No Electrical Load
-No DTC
PA - ENGINE 41
Current Data
Conditions
-No Electrical Load
-No DTC
PA - ENGINE 42
Current Data
Conditions
-No Electrical Load
-No DTC
PA - ENGINE 43
Current Data
Conditions
-No Electrical Load
-No DTC
PA - ENGINE 44
Current Data
Conditions
-No Electrical Load
-No DTC
45
PA - ENGINE
Injector specific data (IQA)
PA - ENGINE 46
Engine Test Function
Engine Test Function is consist of 3 tests, which are tested by Hi-scan.

Those are test for mechanical condition of engine, mechanical condition of injectors and
electrical compensated by ECM
- Compression test
- Idle speed comparison
- Injection quantity comparison
47
Engine Test Function – compression test

PA - ENGINE
48
Engine Test Function – Idle speed comparison

PA - ENGINE
49
Engine Test Function – Injection quantity comparison

PA - ENGINE
M5EF2, A4CF0
Transaxle 2
TM Variation
Engine T/M Area
Volume
Model [cc]
[PS/kg.m] M/T A/T India Europe General
ε-1.1 ● ● ●
1,086 64/9.9
(G4HG) (’07.10) (’07.12) (’07.12)
M5EF2 A4CF0 ● ●
*1,248 77/11.8 -
κ-1.2 (‘08.9) (‘08.10)
(G4LA) ●
1,197 77/11.2 - -
(‘08.9)
U-1.1 ●
1,120 75/15.5 M5CF1 - - -
(U3FA) (‘07.12)
* It is also called referred to as ‘κ-1.25’ to identify with 1,197cc.

Transaxle 3
M/T Main Features

Items PA MXI PA
Model
Engine ε- 1.1 /κ-1.2 ε- 1.0 / 1.1 U - 1.1
M/T code M5EF2 M5EF1 M5CF1
Torque (kgf-m) 12.5 10.0 15.5
Shaft distance (mm) 172 165 189
Length (mm) 347 352.2 378
Weight (kg, dry) 30 24.3 41.6

Transaxle 4
M/T Comparison
Items PA MXI PA
Structure
Case 2 pcs. (C/HSG+T/CASE) 3 pcs. (C/HSG+T/CASE+R/COVER) 2 pcs. (C/HSG+T/CASE)

Shift control CABLE type ROD type CABLE type
1st : Single cone carbon ring, 1st ~ 3rd : Double cone,
Synchro. 2nd : Double cone, All : Single cone 4th ~ 5th : Single cone,
3rd ~ 5th : Single cone R : Anti-Vibration mech.
Clutch Manual Manual Hydraulic
Oil Low viscosity & permanent Permanent Low viscosity & permanent
Transaxle 5
M5EF2 Main Features
Manual cable type clutch

(push type)
Return spring
Double cone synchronizer

Single carbon ring
Transaxle 6
A4CF0 Internal Structure

U/D clutch
O/D clutch Reverse clutch 2nd brake
LR brake
O/D planetary gear Output planetary

gear OWC
Transaxle 7
A4CF0 Main Features
2nd brake Reaction LR brake

plate 2nd brake Reaction LR brake
plate
A4CF0 A4CF1, 2
Transaxle 8
A4CF0 Main Features

Flat torque
converter
Reduced number of disc
The parts of decreased size :

- Overall length
- O/D carrier, O/P carrier
- Input shaft, Output shaft
Changed bearing type
A4CF1&2: Taper roller bearing

A4CF0: Ball bearing
Reduced U/D clutch
Reduced oil pump capacity than

A4CF1&2
Transaxle 9
Specification
Items A4CF0 A4CF1 A4CF2 A4AF3 (MC)
Engine Ε-1.1, Κ-1.2 Γ-1.6 Β-II 2.0 U 1.6 Alpha II
ㆍm)
Torque (kgㆍ 12.5 15.5 24 14.6
Number of OWC 1 ← ← ← ←
Number of Clutch 3 ← ← ← ←
Number of Brake 2 ← ← ← ←
Centrifugal
3 1
Balance
(UD, OD, Reverse Clutch) (Frt. Clutch)
Chamber
Accumulator 4(UD,OD,2nd,LR) 1
6 6
Solenoid valves
(PWM-5, VFS-1) (On,Off-3, PWM-3)
6 with 6 with
Gear Shift Position 7 Modes (P,R,N,D,3,2,1)
O/D switch O/D switch
Transaxle 10
Shift lever & Cluster
No indicator for A/T shift range 6 positions with the

(P, R, N, D, 2, L) in the cluster momentary type O/D OFF
switch
Transaxle 11
Valve Body
•Valve body and spool valve are

from Alloy
• Full line pressure control
• Individual Clutch to Clutch Control
E D
C
* To remove the valve body,

- A type (6x30mm) : 17EA
- B type (6x35mm) : 1EA
- C type (6x40mm) : 1EA
- D type (6x55mm) : 1EA A X 17EA B (except A4CF0)
- E type (6x60mm) : 1EA
Valve body mounting bolt location
Transaxle 12
Solenoid Valve
PCSV - A : O/D or LR Solenoid

VFS Solenoid
PCSV - B : 2nd or REV Solenoid
PCSV - C : UD Solenoid
PCSV - D : Damper Clutch Solenoid
On/Off Sol V/V : Switching PCSV – A from LR to O/D
(Switch on – LR engaged, off- O/D engaged)
* Each solenoid can be interchangeable except VFS (Variable Force Solenoid)

13
Solenoid Valve Current Control

Transaxle
PCSV & SCSV

VFS
Transaxle 14
Accumulator
ⓑ OD (one spring
ⓑ with yellow color)
ⓒ 2nd (two springs

ⓒ with yellow color)
ⓐ UD (two springs ⓓ L/R (one spring

with white color) ⓓ with yellow color)
ⓐ
* Each Spring can be interchangeable except white one

Transaxle 15
Hydraulic Pressure Checking Port
UD
L/R
2ND
LUB
DA
REV
RED OD
* Totally 8 checking ports are used.
- UD : UD Clutch - RED : Reducing Pressure
- L/R : L/R Brake - O/D : O/D Clutch
- DA : Damper Clutch Apply - 2nd : 2nd Brake
- LUB : Lubrication Pressure - REV : Reverse Clutch
16
L/R BRAKE
Transaxle
Pressure Circuit (P/N)
Transaxle 17
VFS (Variable Force Solenoid)

Comparison Purpose
Controlled
Line
pressure Line
pressure Solenoid valve
pressure
Regulator valve Optimum line
Regulator valve pressure
Pump
Pump
Line pressure (bar) Line pressure (bar) Improved

efficiency
8.9 10.5
6.4
4.5
1 2 3 4 Lower fuel
TPS consumption
Gear
Unnecessary high pressure Optimum pressure
* Advantage : To improve fuel consumption by reducing unnecessary high pressure

Transaxle 18
VSS (Vehicle Speed Sensor)
VSS is eliminated in A4CF0. Instead of this, output speed sensor (PG-B) is used for PCM.
Transaxle 19
FPC (Flexible Printed Circuit) Harness
10P CONN
OTS
VFS
10P CONN INLINE CONN OTS VFS

INLINE CONN
PCSV CONN
PCSV CONN
(A4CFx) (A4AFx)
(OTS)
Transaxle 20
Operation table
Items Solenoid Valve (0%:OFF, 100%:ON)
PCSV-A PCSV-B PCSV-C PCSV-D ON/OFF

Range Operation SOL.
(OD&LR) (2ND&RVS) (UD) (DCCSV)
P, N LR OFF ON ON OFF ON
(D,2) 1st UD *OFF ON ON OFF OFF *ON OFF
(D,2) 2nd UD, 2ND ON OFF OFF ON OFF
(D) 3rd UD, OD OFF ON OFF ON OFF
D-4 OD, 2ND OFF OFF ON ON OFF
R LR, RVS OFF OFF ON OFF ON
(L) 1st UD, LR OFF ON OFF OFF ON
* Vehicle stop Wheel rotates

Transaxle 21
Input & Output
Battery Power VFS
GND PCSV – A(LR&OD)
PG-A & PG-B PCSV – B(2nd&REV)
OTS PCSV – C(UD)
Output
PCM
Input
(TCM)
Inhibitor Switch PCSV – D(DCC)
O/D OFF Switch SCSV – A (On/Off)
Stop Lamp Switch Vehicle Speed

- Cluster
- MDPS control module
CAN Communication - BCM
Transaxle 22
Input (PG-A) and Output Speed Sensor (PG-B)
PG-A
PG-B
VSS (From PCM to Cluster)

Transaxle 23
PG-A & PG-B Failure
Failure Detected
A to B : 1.08s
* When PG-A or PG-B failure is detected, electrically gear is fixed to 3rd gear.
Transaxle 24
OTS (Oil Temperature Sensor)
* When OTS failure is detected, OTS current data sets to 80℃

℃.
Transaxle 25
Solenoid Valve Circuit
PCM
UD(+)
(PCSV-C)
2nd&Rev(+)
(PCSV-B)
LR&OD(+)
(PCSV-A)
On/Off(+)
DCC(+)
(PCSV-D)
VFS(+)
KEFICO (Epsilon 1.1)

Transaxle 26
Solenoid valve control
R D
* Solenoid failure checking for 80ms.

Transaxle 27
Solenoid Valve Fail (3rd Gear Fixed)
A to B : 1.8s
* SCSV solenoid valve shorts to ground during driving under 3rd gear resulting in
mechanical 3rd gear fixed condition.
28
Resetting Auto T/A Values

Transaxle
Transaxle 29
CAN Communication
PCM ABS
(ECM) (ESP)
Resistance
Terminal
OBD Connector
I/P junction panel

PA ESP
ESP 2
Comparison
Item MGH 10 MGH 20 MGH 25 MGH 40
Model
Application LC, XD, SM GK, FC JM EN, TQ, PA
1999 (ABS) 2003 (ABS)

MP year 2001 (TCS) Aug. 2006 (ESP)
2000 (TCS) 2004 (ESP)
LFC + MSC +PBA + LFC + MSC + PBA +
MIRC MIRC + ROP
LFC: Linear flow control
Key Points On-Off valve control MSC: Motor speed ROP: Roll over
control
prevention (not for
PBA: Panic brake assist
MIRC: Modified PA)
independent rear control
ESP 3
Comparison
Items ABS ESP
HECU Assembly
Wheel speed sensor
Yaw & lateral G-sensor -
Pressure sensor - Built in type
Steering angle sensor -
Longitudinal G-sensor
(4WD only)
4
ESP
ESP Components
ESP 5
Components of HECU
Motor
Valve Block
MGH-40 ABS
Solenoid
Valves
Pump
ABSCM
Motor
Accumulator
Solenoid
Valves
Pump
Pressure
sensor
ESPCM
MGH-40 ESP
Accumulator
ESP 6
Features
LFC (Linear Flow Control)
LFC Control Range

On/Off LFC
µ
Pressure
Overshoot
Skid
Pressure On/Off Control Range
∆P
Pressure
Undershoot
Slip
ESP 7
Features
MSC (Motor Speed Control)
Vehicle Speed
Wheel Speed
Big Dump
Rich brake oil Motor RPM is high
Wheel Pressure flow in LPA
Vehicle Speed
Wheel Speed
Small Dump
Poor brake oil Motor RPM is low
Wheel Pressure flow in LPA
ESP 8
Features
MIRC (Modified Independent Rear Control)
- Enhancement of braking performance
- Independent pressure control according to rear wheel movement

(for the vehicle safety, the control is limited : pressure difference RR vs. RL is less then 20 bar)
- Application : ABS, ESP
Master Pres.
Pres Rise Pres Rise

Limitation Limitation
P_r1
P_r2
Gain in Braking
Performance
ESP 9
Inputs & Outputs
MGH-40 ESP
WSS (4EA) Motor Pump
Solenoid Valves
Steering Angle Sensor
EPS OFF Warning Lamp
Yaw rate & Lateral G- sensor
(CAN) ESP Function Lamp
ABS Warning Lamp

Pressure Sensor ESPCM
EBD Warning Lamp
Brake Switch
CAN
Diagnosis with scan tool
Engine torque reduction request
ESP OFF Switch Gear hold request
ABS Active Signal
Wheel speed information and so on.
Longitudinal G- sensor
(4WD only)
ESP 10
Active Wheel Speed Sensor

• Type: Active type (Hall effect)
• Power supply: 12V
• Air gap: 0.2~2.0mm
• Frequency: 1~2,500Hz
• Possible to detect 0km/h
• Not sensitive to the noise and air gap.
Front Rear
OUTPUT SIGNAL MAX TYPICAL MIN
LOW ER SIGNAL ILOW (m A) 5.9 7 8.4
UPPER SIGNAL IHIGH (m A) 11.8 14 16.8
SIGNAL RATIO IHIGH / ILOW 1.85 or m ore
OPERATING FREQUENCY 1 ~ 2500 Hz
OPERATING DUTY 30~70%

ESP 11
Yaw rate & Lateral G-Sensor

• Power supply: 6.5~18V
• Signal output: CAN interface
• G sensor : -1.5~1.5g
• Yaw sensor: -75~75°/sec
CAN-Hi
CAN-Lo
[Location] – Under passenger seat [Output Signal]

ESP 12
• Location: Inside steering wheel

• Calculate the steering amount and direction
• 3 Input signals (ST 1, ST 2, ST N)
• ST N detects the neutral position of steering wheel
Sensor connector
• Sensor type : Photo interrupt type

• Sensor output type : Open Collector Type
• Output pulse quantity :45pulse
(Pulse cycle 8°)
• Supply voltage :IGN1(8~16V)
STN • Output voltage :1.3≤VOL ≤2.0V,

3.0≤VOH ≤4.1V
Photo diode (ST1,ST2, STN)

13
STN
[ST1, STN]
ST1
[ST1, ST2]
ST2
ST1
ESP
Output signal
ESP 14
Diagnosis & Troubleshooting

Checking procedure before diagnosis
Before diagnosis with a scan tool, confirm the operation of warning lamps is normal.
Turn the IG key OFF ON,
1. If ABS/EBD/ESP OFF lamps turn on for 3 seconds and turn off

: warning lamps and ABS/ESP systems are okay]
2. If ABS/EBD/ESP OFF lamps stay off

① Remove the ABS/ESP Connector.
② IG key ON
③ ABS/EBD stays off warning lamp circuit error check the cluster & wiring
④ ABS/EBD stays on warning lamp circuit normal, ABS error diagnosis with HI-SCAN
Caution during vehicle service

1. Remove the ABS/ESP connector before ECM or TCM work.
(if not, CAN related DTCs will be memorized on the ESPCM)
2. Before Remove the connectors, turn the ignition off.

ESP 15

Motor/Valve/Fuse check
Error
Fault Type Cause Checking Procedure
Code
Motor Short 1. Check the motor power (BATT2) and fuse/wiring (10~16V)
to BAT/GND Power supply
2. Check the Chassis GND & ESPCM GND :
Motor Open Motor fuse less than 10mΩ
C2402
Motor Fuse Defected 3. Drives over 20kph Warning lamp ON check 1
Open motor Okay
Motor Lock Replace the HECU
Valve Relay
Power supply
C2112 Open/Short
Valve Relay 1. Check the valve relay power (BATT1) and fuse/wiring
Fuse Open
(10~16V)
Fuse
Open/Short
2. Check the Chassis GND & ESPCM GND : less than 10mΩ
C2380 Solenoid
Leakage
Valve
Current
ESP 16
CAN check
Error
Code
1. Check the resistance between the CAN High and the
CAN Bus CAN Low (Normal : 60 Ω)
C1616 CAN BUS
OFF
2. If the resistance is abnormal check the wiring condition
No ECM 1. Check the ECM and TCM connectors and wiring condition
C1611 Message message
2. Check if there are CAN related DTCs from ECM & TCM
C1612 Timeout No TCM
Message 3. Read the CAN data from TCM current data with HI-SCAN
CAN H/W
C1605 CAN H/W Error 1. Replace the HECU.
Fail
ESP 17

Pressure sensor check
Error
Code
Sensor
C1235 Sensor circuit 1. Replace the HECU.
Open/Short
Sensor 1. Check if the brake light switch & brake switch & wiring is
C1237
Signal Sensor normal
Error 2. If okay, replace the HECU.
ESP 18

Yaw rate & Lateral G sensor
Error Code Fault Type Case Checking Procedure
1. Check the resistance between the CAN High and the CAN Low
Sensor CAN
C1644 CAN BUS (Normal : 60 Ω)
BUS OFF
2. If the resistance is abnormal check the wiring condition
1. Check Sensor connector & wiring

Sensor CAN
Sensor CAN
C1643 Message 2. Check the CAN signal
Message
Timeout
3. If the CAN signal is okay but problems occurs replace the sensor
1. Check Sensor connector & wiring
2. Check if sensor installation is okay.

Abnormal Offset, Noise
C1283 3. Remove the sensor mounting bolts and IG on. Move the sensor and
Signal Stick
read the current data of HI-SCAN.
4. If problem occurs, replace the sensor
Sensor CAN Sensor CAN

C1647 Replace the sensor
H/W Fail H/W
Sensor Self Test

C1282 CBIT Fail Replace the sensor
Error
Body Electrical 1
Body Electrical
Warning lamp
control
Power window
Ignition key control
reminder
Tail lamp auto cut Keyless entry &

Anti-theft control

Body Electrical 2
ETACS Function
Europe
General Middle East China
SBR NON-SBR
Seat belt Buzzer X O X X X

warning timer Indicator O O O X O
Seat belt reminder X X X O X
Crash door unlock O O O O O
Key operating warning X O X X X
Tail lamp auto cut O O O O O
Ignition key reminder O O O O O
Central door lock/unlock O O O O O
Door lock / unlock by Tx O O O O O
Power window timer O O O O O
Anti-theft (Burglar alarm) O O O O O
* O : Apply X : Not apply
This information can be changed without prior notice.

3
Antenna
Body Electrical
ETACS Location
Body Electrical 4
Seatbelt Warning
Driver seat belt warning lamp and warning sound condition
ON
IG Switch
OFF
OFF Unfasten
Seatbelt Switch
(Normal close) ON Fasten
T1 T1
ON
Chime Bell T2
OFF
ON
Seatbelt Warning T3
Indicator OFF
T1 T1 T1
T1 : 6±1s T2 : 0.45±0.1 s ±0.1s

T3 : 0.3±
Body Electrical 5
Crash Door Unlock
If the airbag deployed signal is inputted to the ETACS when the door is locked,
the unlock signal is executed immediately for safety.
On
Ignition
Switch Off
T1
Air Bag Normal

Signal
Deployment
T3
T2
On
Door Unlock
Relay Off
T1 : 0.2s T2 : 40 ms ±0.5S
T3 : 5±
Body Electrical 6
Key Operated Warning
Chime bell output continuous, when driver door is opened if IG key is in the key cylinder.
On
Key In
Switch
Off
Driver Open
Door
Switch Close
On
Buzzer
(Chime Bell) Off
Body Electrical 7
Tail Lamp Auto Cut
Auto Cut Auto Cut
On
Key In
Ignition Key
In Switch
Off
On
Tail Lamp
Switch
Off
Open
Driver Door
Switch Close
On
Tail Lamp
Relay
Off
Body Electrical 8
Ignition Key Reminder
This function is to prevent vehicle from door lock if IG. key is inserted into key cylinder.
On
Ignition Key
In Switch
Off
Driver, Open
Passenger
Door Switch Close
Driver, Unlock
Passenger
Door Lock
Lock
Switch T1
T4
T2 T3
On
Door Unlock
Relay
Off
T1 : 0.5S T2 : 1±±0.2s
±0.1s
T3 : 0.5± ±0.1s
T4 : 0.5±
Body Electrical 9
Keyless Entry & Central Door Lock/Unlock
Transmitter On
Signal
Off
Driver Door On
Unlock Switch
Off
Passenger On
Door Unlock
Switch Off
On
Door Lock
Relay Off
On T1
Door Unlock
Relay Off
T1
±0.1s
T1 : 0.5±
Body Electrical 10
Power Window Timer
ON
Ignition
Switch
OFF
Driver, Open
Passenger
Door Switch
Close
ON
Power Window
Relay
OFF
T1 T1
±3S
T1 : 30±
Body Electrical 11
Burglar Alarm System – Arm Mode
All Doors : Transmitter Arm Wait

Arm Mode
Close Lock Signal (30 sec)
Door Open
Disarm
Or Unlock
Body Electrical 12
Burglar Alarm System – Auto Lock Timer 1
All Doors: Close Transmitter Auto Lock Arm Wait

or Arm Mode Unlock Signal Timer 1 (30sec)
Arm Mode
Body Electrical 13
Burglar Alarm System – Auto Lock Timer 2
All Doors : Close Transmitter Auto lock

Pre Arm
Hood : Open Unlock Signal Timer 2
Arm Wait Hood: Hood:

Arm Mode
(30 Sec) Close Open
Pre Arm
Body Electrical 14
ICM ( Integrated Circuit Module)
A
B
C
A : Door Lock / Unlock Relay (Twin) D
B : Burglar Alarm Relay (Start Inhibit)
C : Burglar Alarm Horn Relay
D : Hazard Lamp Relay
MDPS
MDPS 2
System Structure
Vehicle speed
PCM(ECM)
Torque Sensor
ENG speed
MDPS Control
Module
Reduction gear
(Plastic worm wheel) EPS Motor
MDPS 3
Torque Sensor
MC PA
Contact type Non-Contact type

[Potentiometer] [Linear Hall]
Voltage Main, Sub signals have Voltage Main, Sub signals have same
cross type opposite phase each other straight type phase each other
MDPS 4
Torque Sensor
Hall IC
Input shaft Rotor
Rotor
Stators
Hall Sensor
S N S
Stator N N
S S
[Internal Structure] [Sensor principle]

MDPS 5
Engine Speed & Vehicle Speed Signal

Vehicle speed
PCM(ECM) MDPS Control
Module
Eng. speed
Engine speed from PCM(ECM) Vehicle speed from PCM(ECM)

MDPS 6
Power Supply & Warning Lamp
Engine room junction box (‘MDPS 80A’)
MDPS Warning Lamp
• IG ON, Engine Stop: Keep ON

• Engine Starting : Turns off 2sec later after engine
I/P junction box (‘Cluster 10A’) starting in normal condition.
MDPS 7
Motor
• Brush-less type DC motor (vs. brush type)
- Small size and light weight
- Higher rotating speed
- More complicated control is required
(higher cost)
• Max. Current: 65A
Coil
Permanent
magnet
Permanent
magnet Stator
MDPS 8
MDPS Control Module
• System Supplier: MANDO

• Thermister to detect the temperature is
embedded in control module.
Motor connector
9
MDPS
Communication
PA SRS (SIEMENS)

De-powered Airbag System (General/EUR)
Introduction
Introduction

Application
Option GEN M/East Europe REMARK
DRIVER Depowered O O S
PASSENGER Depowered O O O
Side Airbag (FR) - - O
PAB ON/OFF Switch - - O
O : Option S : Standard
PA Airbag System
Inputs and outputs
Driver airbag
Passenger airbag
Deactivation switch Passenger airbag
Battery (+) Side airbags
Belt pretensioner
ACU Airbag warning
Front impact sensor
lamp
Passenger airbag
deactivation lamp
Side impact sensor

Crash output to BCM
K-Line
PA Airbag System
Airbag Thresholds
Driver Front Airbag
Unbuckled/Buckled
Driver Airbag
PT Airbag
No Fire Crash No Fire No Fire

Crash Severity
Must Fire Crash Fire Fire
Passenger Front Airbag
Unbuckled/Buckled
Passenger
PAB On-Off Switch On (Enabled) PAB On-Off Switch Off (Disabled)
Airbag
PT Airbag PT Airbag
No Fire Crash No Fire No Fire No Fire No Fire
Must Fire Crash Fire Fire Fire No Fire

PA Airbag System
Airbag Thresholds
Driver Side Airbag (DSAB)
Thorax and side airbag

Driver Seat
PT Side airbag
No Fire side crash No Fire No Fire

Crash Severity
Must Fire side crash No Fire Fire
Passenger Side Airbag (PSAB)
Passenger Seat PAB On-Off Switch On (Enabled) PAB On-Off Switch Off (Disabled)
Thorax and head side airbag PT Side airbag PT Side airbag
No Fire side crash No Fire No Fire No Fire No Fire

Crash
Severity
Must Fire side crash No Fire Fire No Fire Fire
PA Airbag System
ACU (Airbag Control Unit)
The primary functions

① Crash Detection
② Activation of the front airbags, Side airbags and belt pretensioners
③ Monitoring of the airbag restrain system
④ Indicate system readiness and faults to the drive by means of a fault warning lamp
⑤ Facilitate servicing capability via a serial diagnostic communication interface
PA Airbag System
DAB (Driver Air Bag)
Resistance: 2 ±0.3Ω
All-fire current: 1.2A for 3ms.
No-fire current: single pulse of 0.4A for 10 sec
Cyclic test current: 100mA for continuous

PA Airbag System
PAB (Passenger Air Bag)

PA Airbag System
SPT (Seatbelt Pre Tensioner)

PA Airbag System
PAD (Passenger Airbag Deactivation) Switch – EUR Only
Pin No Description
1 Ignition 1
2 Earth-Glove Box
3 Ground – ACU I/F
4 ACU Interface Line
PA Airbag System
FIS (Front Impact Sensor) & SIS (Side Impact Sensor)
Name HMC Number Sensor Figures
Side 100g,
95920-0X000
Impact Sensor x-axis
Front 250g,
95930-0X000
Impact Sensor x-axis
Output
Airbag (SRS) Warning Lamp Operations
(Active fault or historical fault counter is greater or equal to 10)
(Normal or historical fault counter is less than 10)

( PAD Lamp operation during Phase-up )
PAD Indicator Operations
Output
Output
Crash Output
The required command mode implementation is high/low voltage level.
When the fire decision is made by ACU, crash output stays low voltage during
200ms like below.
(Crash Output Signal)

HI-SCAN diagnostic tree
Diagnostic Trouble Crashing Identification Passenger Airbag

Codes Information Check Realtime Info
Internal faults can´t be erased
Front Crash Information
Driver Crash Information Side Crash Information Passenger Crash Information

Diagnostic Troubleshooting Flow
Gathering information
from customer Verify complaint
Reoccurs Does not reoccur
Check DTC Check DTC
DTC displayed DTC displayed No DTC

No DTC or can’t
communicate with
Hi-Scan
Record DTC then try to
erase them
Recheck trouble symptom
No DTC
Check displayed DTC
DTC displayed
Inspection chart for

Inspection chart for DTC Intermittent malfunction
trouble symptom
Air conditioning 1
Air conditioning

Air conditioning 2
General Information
PA
Items
Epsilon Engine U(DSL) Engine
Compressor
HS-11 HS-09
(Fixed Type Swash Plate)
Refrigerant/Oil quantity 450±25g
Sub-cool type
Condenser
(Condenser, Receiver Drier Integrated)
APT
Pressure Detecting
(Automotive Pressure Transducer)
Cooling Fan Control Resistor
Blower speed control Resistor

Air conditioning 3
Components
Inlet Actuator
Heater Core
Air Filter
Thermistor
Evaporate Core Blower Motor
Resistor
PTC Heater
Air conditioning 4
Heater Controller
Type A (sliding) Type B (3-Button) Type C (5-Button)
Compressor
Epsilon Engine U(DSL) Engine

HS - 11 HS - 09
Air conditioning 5
Air Filter
1. Description
Employing combination filter, dust and odor in the air is effectively removed.
2. Life Time
Filter replacement period is 5,000 ~ 12,000km. But this can be shorten if
the road condition is bad causing more dust and black smoke in the air.
Air filter cover

3. How to replace
-. Remove the glove box.
-. Pull the locking part of the air
filter cover
6
Air conditioning
Blower Speed Control
Air conditioning 7
Intake Actuator
PTC Heater
Control Module
Circuit Diagram 1 2
M
Terminal 1 2
1 2 Intake FRE REC

Air conditioning 8
Fin Sensor (Evaporator Temp. Sensor)
RHD Sensor position

: 8th row, 40mm
A/C S/W
ECM
PRESS 2
S/W
1 3
LHD Sensor position
: 8th row, 40mm
Air conditioning 9
APT Sensor (Automotive Pressure Transducer)

Approximately 4.8V
Output
Approximately
0.2V Normal
operating range
1.0 32.6
Guard
(Ground) Detect
Housing Source
Terminal
Sealant Ceramic Substrate Ceramic Substrate
Pin Flexible circuit

Ceramic Diaphragm Pressure
Ceramic
Silver epoxy substrate
Distance (D)
O-ring Ceramic diaphragm
* The main function of APT sensor is detecting the refrigerant pressure (distance d).
Air conditioning 10
PTC (Positive Temperature Coefficient) Heater
#3
#1
#2
Glow
plug
relay
PTC Heater PTC Heater Relay
Intake
Actuator
PTC Heater
Control Module
Air conditioning 11
PTC (Positive Temperature Coefficient) Heater
Battery Voltage
8.5V – 12.5V
Engine rpm
above 700
ECM
Intake Air Temp. (MAF)
below 5C°°
Relay 1 On PTC-Heater Relay 1

Coolant Temperature
below 70C°°
Blower Motor
ON Blower Motor On
PTC-Heater Relay 2
PTC Heater
Battery Voltage Control Module
8.5V – 12.5V PTC-Heater Relay 3

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Engine T/M Area

ε-1.1 1,086 64/9.9 M5EF2 A4CF0 ● ● ●

U-1.1 1,120 75/15.5 M5CF1 - - ● -

Epsilon 1.1L engine is already used for Santro(Atoz)

Epsilon engine Engine ε-1.1

• SOHC In-line 4 cylinders (12 valves)

Traditional torque method is used. To keep proper installation, mentioned

Inlet Cooling System

Thermostat opening temperature is 82℃℃.

Oil Pump and Oil Pressure Switch

At engine idle condition after warm up, normally

Oil pressure switch is screwed near engine oil

Return Less Fuel System (RLFS)

Inspection by test lamp Sound inspection

Ignition Coil and Spark Plug

Type Mold Dual Coil

Ignition Coil Primary Ω±10%

Input & Output

For European Market

10. WHEEL SPEED

For General Market

At ignition on condition, it shows 3.8 ~ 4.2 V which is converted to atmospheric pressure.

When IAT fault is detected, current data shows -40℃ an a default

TP Sensor (Lever type)

Hall IC type CKP sensor is used. ECM

CMP sensor is also used from Hall IC.

It distinguishes the cylinder No. by

It is located near ignition coil. Camshaft

[CMP with CKP Sensor Waveform]

Rear or Down Stream

Zirconia type oxygen sensor is used.

Engine knock control is used to constrain the knocking.

• Maximum Retard Limit : 12˚

• When knocking is detected : Initially retard 3˚

Wheel Speed Sensor

M/T Input Variable ECU PIN NO.

Vehicle Speed Sensor

- Vehicle speed sensor is applied on MT only.

- In the case of AT, the vehicle speed sensor is eliminated.

T/M Type Vehicle speed from ECU PIN NO.

ISA (Idle Speed Actuator)

For Evaporative gas monitoring.

PCSV is installed between the canister and the intake manifold, it

Copyright by Hyundai Motor Company. All rights reserved.

• VGT Turbo Charger

4 valve DOHC Timing chain

Timing System DOHC 4 Valve

CAM operating type : 2 Chains

Balance shaft Balance shaft is operated by gear

Intake / Exhaust manifold

High Speed Low Speed

Fuel system – location / component

Max. Pressure : 1600 bar

Fuel system – High Pressure Pump / Common Rail

High Pressure Pump Common Rail

Fuel system – Injector

Ampere for solenoid control

Idle condition 1500 rpm 3000 rpm

Idle condition 1500 rpm 3000 rpm

Idle condition 1500 rpm 3000 rpm

Idle condition 1500 rpm 3000 rpm

Idle condition 1500 rpm 3000 rpm

Idle condition 1500 rpm 3000 rpm

(D,2) 1st UD OFF ON ON OFF OFF ON OFF