manual hyundai tucson

8/2/2019 Manual Hyundai Tucson

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HOW TO USE

THIS MANUALINTRODUCTION GI-1

SYMBOLS. GI-6

TROUBLESHOOTING INSTRUCTIONS GI-8

WIRING REPAIR GI-12



INTRODUCTION E7DC7F9C

INTRODUCTION (1) GI-1

- . - . - . . _ . _ . _ . _ . _ . ,IIIIIIIIIII

~IEMD3IPHaro 0 81

! . - : ; - ~ : : : - ; : ( : ~ : : ~ : ~ ; ; ; ~ : [ : ~ l ~. - - - - - - - - - - - - - - - - - - - - - - - - - - - - t Q D r ~ ~ ; ~ ~ i i e ~ ~ rL t_-:~c__ _ _ J ocations

~ E : : ' ~ : ~ : ~ ~ L M _ ' _ ' ,_-i---__..L.

"= ' " ':"BATTERY BWY

®Wire color +__; ; G ; . ; R O ; ; . U ; . ; N ; ; ; D ~ . . ; G R ; ; . ; ; ; O ; ; . U N . ; ; D ~ _ ---ll-__"'Q

1 E E m l P H O T O 0 7 1

SlY

OVERRUNNING

C LU TC H

5 E M0 2i PH OT O 0 81

Connector

® classification

number

Connector

.... --------+-@terminal

numberSeeGr c u n dDist r ibut ion

6 MT0-1

r - , E T A C M: : IPHOTO 0 & 1

L__ I

® Distinguish harness from harness connection connector

GGI01



INTRODUCTION


Connector

® configurations(components)

Explanation of

connector code

STARTING SYSTEM

STARTING SYSTEM (2) S0360-2

MOS M06 M11 M13

6~-

l-=-Jl

~

J=L '

1 1 2 1 ~ t W f 4 T 3u u * 1 1 1

H * al7 6 1 5 11 6 1 * I a 1 9 1 1 0

KET_09011_D4F _ w KET_0901l_10M_W KUM_AR_04F _ w K ET _ o90 11 _1 O F _W

M67 M81

[rrJ 1 m BLANK BLANK

6

AM P_Pl.M2_02F _8 KET_09011_06M_W

M05a: Connector manufacturer

b :Terminal series number

c :The number ofconnector terminals

d :Connector distinguishing ~Female Pin: F

Male Pin :M

B (Black)

Br(Brown)

G (Green)

Gr(Gray)

L (Blue)

R(Red)

W(White)

Y (Yellow)

e : Connector colorabbreviations

K ET _ 09 01 l_ 04 F _ V i.

/11\\

GGI02



INTRODUCTION


CDPages by system! Name of Schematic diagram

"Each page is consisted of clrcuts by system. This schematic

diagram includes the path of elect rici ty f low, connect ion condit ionfor each switch, and the function of other relevant circuits a t once.

It is applicab le to real servi ce work.

"It is very importan t to understand re levant clreu fts exactly before

troubleshooting diagnosis.

"Circuits by system depends upon part number and are ind ica tedon schematic diagram index.

®Connector configurat ion (components)

"The connector figure o f components in the schematic diagramby system is indica ted on the last page of schematic d iagram.

"It shows the front of the connector on the harness side when not

to the harness connector. The terminal number on each connectorcan be obtained by following the patte rn used in @ connector view

and numbering order. Unused terminals are marked w~h an aster isk (*).

@Connector configurations (connection between harnesses)

"When connecting the harness with connector be tween harnesses,

it shows female and male connectors and indicates them on theconnector configurations group.

EM02

@)Componentlocations

"To find the components easily, a component locations diagram isindicated with "PHOTO NO" on the lower portion of the component name.

"To make it easy to distinguish connectors, the connector in thepic ture is indicated being installed inthe vehic le.

PHOTO 03

@CONNECTORVIEW AND NUMBERING ORDER

Female Male Remarks

~Housing Pin

I t is notthe shape of the connector

housing, but the connector pinthat distinguishes between male

or female connectors.

When numbering female and maleconnectors, refer to the numbering

order in the following table.f---------+----------J Some connectors may not follow this

method of numbering order.

For individual detailed numbering,refer to the CONNECTORCONFIGURATIONS.

. U I T l n

Numbered in order from upper

right to lower left

Numbered in order from upper

left to lower right

NOTE

UNLESS OTHERWISE STATED,ALL CONNECTORVIEWS ARE FROMTHE TERMINAL SIDE OFTHE CONNECTOR.

GGI03



INTRODUCTION

INTRODUCTION (4)

@CONNECTOR IDENTIFICATION

A connector identification symbol consists of a wiring hamess location

classification symbol correspond ing to a wir ing harness loca tion andnumber corresponding to the connector .These connector locations can be found in the HARNESS LAYOUTS.

For example:

GI-4

® WIRE COLOR ABBREVIATIONS

The following abbrevia tions are used to iden tify wire colo rs in the

circuit schematics.

Symbol Color of wire Symbol Color of wire

B Black 0 Orange

Br Brown P Pink

G Green R Red

Gr Gray W White

L Blue Y Yellow

Lg Light Green Pp Purple

T Tan LI Light Blue

E 10 -1

1 1 Number correspondlnq to sub-connector ,5'" Number)

Number corresponding to main connector (Serial Number)

Symbol indicating wir ing harness (Engine wir ing harness)

* ®I@: Black stripe with yellow ground (2 colors)

1 t _ _ _ _ _ _ _ _ _ _ . ,the color of the color ofbackground stripe

< Z l HARNESS CLASSIFICATION

Electrical wiring connectors are classified according to the wiring parts in theHarness Layouts.

Symbol Harness name Location

CControl, Injector harness Engine compartment,

Passenger compartment

D Door harness Door

E Engine, Battery harness Engine compartment

F Floor harness Floor, Trunk

A/Bag, A/ C harness Passenger compartment

M Main, Roor, Sunroof harness Passenger compartment, Roof,

Under crash pad

R Tail gate harness Tail gate

• It depends on vehicles, it is necessary to check the harness name symbol

on the harness layouts fo r detailed symbol .

NOTE

Connectors which connect each wiring harness are represented by

the following symbols.

For example:

M R 01

T T lNumber corresponding to main connector (Serial Number)

CRear wiring harness

Main wiring harness

JUNCTION BLOCK IDENTIFICATION

A junction b lock identification symbol consists of a wir ing harness

location c lass if ication symbol corresponding to a wir ing harness locat ionand number corresponding to the connector in the junction block.

For example:

'-tLConnector name

Abbrev iation of the word

"Passenger compartment junct ion block"

GGI04



INTRODUCTION


HARNESS LAYOUTS

Harness layouts show the routing of the major wiring harnesses,the in-li ne connectors and the sp lices between the major harnesses.These layouts wi ll make elect rical t roubleshooting eas ier.

M29

M30

Passe nge rC o m p a r t m e n tJunction Block

(I/P-E.F.G.H.J)

Z02----""".

GGI05



SYMBOLS E552AD1C

SYMBOLS (1) GI-6

. e o -Symbol Meaning . - Symbol Meaning

. . . .Symb," Meaning

Sec- S y " ' ' " _ng.on .on .on tlon

1 .., •

~

~C(J~~lIClor S ho ws t he n am e of e a ch c o nn e ct e r H

rr

This r ep re sents RFI (Radio Dou l1 e f il am en tA s o lid l in e m e a ns t he e nt ir e 1 ° T N O I i - 2 ~ o n 1 I1 e c cr re c ne nt l oc at io n i nd ex I

L

c om po ne nt i s s h ow n .c t "__F.mol. far reference.

E Frequency Interference)0 L

"Sh ie ld in g a round a w ir e.

A"<n~""I'"Indicateslhenumberof 0

N" The shi el di ng is a lways . .

c pcO lTEIspond i lg t e rm ina l

W

E (Olly relevart 1enninal en the I '" connected t o ground. P Sing le f i lament

i--i A b ro ke n l in e i nd ic a te s o nl y c

+ - ~ l "c o rr es p on d il g s c he m at ic d ia l7 am ) . R

T EI I par t o f th e componen t is T he d as he d- lin e m ea ns e ec h ofI I shown .0

two w i' es c cn ne ct wi ih s am e J

f_. __ - R

0" n

connector(E35)I

0Dioder r - N

mh is means the connector T I

Cc o nn e c ts d ir e c1 1 y t o t h e A wavy line means the c Thi s i s a connec1o r showi ng

f)0component. l wire is broken but 0 t he joi ni ng wires . Led diode

N0 i s t o be con ti nued . N

0E

t"

Wire insula1 ion i s yel lowc

-

. . T E Zener diodew ith a r ed s tr ip . 0

This indica1es the connector WR

0-connect s t o a lead (pigt ai l) ,

F rom C52

Pw ir ed d ir ec tly to t he com-

i TCurrent path is continued on

B~

t he same page or ano th erponent.

p age.T he a rr ow shows t he • I~",~.I- Power supplied at all timesNPN NP N0 I L f ~ - - - : E ~ ! f E &irec1ion of current f low. 0

You should look for the "A"w I t O M4=-- Name ",

N i n t he marked posHion . B i ~~+---+--apacityB~

L L s . . _ _ _ J0PNP PN P

" 1w

EThis i nd ica1es a saew termina l

A w ir e connects to ano th er

0

n the component .c ir cuH. The w ir e is shown

N Eaga in on th at c ir cuH wh ich

Name of Cir~uit1he arrow is point ing.

SII~~

Thi s means power i s suppl ie d G

-~.".....___ wtth the igni1ion on posi1ion. ET

~,l~ Wi re cho ices fo r op1i on s o r

-~,~N

...IIII l IIIDIIII

d if fe rent model s are labeled U : I~ This means the s hort barE

: r : rR

-and shown w it h a "cho ice" : 2 '~.-n., connects 10 other1uses. A .~i'Tm'i1

This ground symbol (dot and bracke1like 1his. • I ' L C = Identi1icationL

03 l ines over1apping 1he com-

~

ponen1) means the housing • Et_y___ I

Current ra1ingC

: F -Spli ce s a re number ed and 0

of t he componen1 i s a tt ached Pshown as a dot w i1 h c ir cle .

. . Switch (1contact point)L P

-= - 10a me ta l pa rt of 1he vehicle. I The exactlocation and c on- 0C

nection of th ese spl ic es may NE E

The name of the componen1 • vary among vehicles . C

~

N0

T[ ] ' T O ~ _ ~}-

PN

~

LAMP appear s nex t to it s uppe r r ig ht ONSWrTCH

corner.G This symbol means 1he end WE Control battery power at alltines •~ R

of the wire is a1tached to a EC y

L0 RT . . Heater

Shows the number 01pi ct ures U metal par t o f t he veh ic le . 0 •for component locat ion.

N R 00

G D aL

GGI06



SYMBOLS

SYMBOLS (2) GI-7

. . . . .Symbol Meanlnl i l

see-Symbol M e a n i n g

don tlon

I

ensor

$Condenser

GEN

ERAL

a af Jc

G0

Sender MSpeaker

E p

N0

NE E

RNT

A S

L

~

S

c : 9C I " ,ectorM

H o rn , B u zz e r, S ir en ,•0

Chine8el

ML

""P

0

N

~ ~

E

N SolenoidNo n ne . ll y o p en c c rr ac t

T

S

S

~

1h is is a re la y s ho wn w ith n oy

currentilo ....ng thrc:ugh its cdl

$R When a amant flews 1hrc:ugh

ME

c oi l, c on ta ct w i ll t og g le .

• L0 Mota

A

t 1 JY

D io de i nt er io r r el ay

IT ] Battery t 1 J R e s is t an c e i nt e ri o r r e la y

GGI01



TROUBLESHOOTING INSTRUCTIONS EFAE8AD9

GI-8ROUBLESHOOTING INSTRUCTIONS (1)

TROUBLESHOOTING INSTRUCTIONS

TROUBLESHOOTINGPROCEDURES

The fol lowing five-step t roubleshooting procedure is recommended.

1 . Verify the customer's complaints

Turn on al l the components in the prob lem circui t to check the accuracy of the

customer's complaints. Note the symptoms.

Do not begin disassembly or testing until you have nar rowed down the probab le

causes.

2. Read and analyze the schematic diagram

Locate the schematic for the problem circuit. Determine how the circu it is

supposed to work by tracing the current paths from the power source through

the system components to ground. If you do not understand how the c ircuit

should work, read the ci rcuit operation text. Also check other ci rcuits that share

with the prob lem circuit. The name of c ircuits that share the same fuse. ground.

or switch, fo r example, are referred to on each d iagram. Try to operate any

shared circuits you did not check in step 1. If the shared circuit works. the

shared wiring is okay, and the cause must be within the wiring used only by the

problem circuit.

If several circuits fail at the same time, the fuse or ground is a like ly cause.

3. Inspect the circuit! component with the problem Isolated

Make a circuit test to check the diagnosis you made in step 2. Remember that a

logical, simple procedure is the key to eff icient t roubleshooting. Narrow down the

probable causes using the t roubleshooting hints and system diagnosis charts.

Test fo r the most l ike ly cause of fa ilure first.

Try to make tests at points that are eas ily accessible.

4. Repa ir the prob lem

Once the problem is found, make the necessary repairs.

5. Make sure the circuit works

Repeat the system check to be sure you have repaired the problem. If the

problem was a blown fuse, be sure to test all of the circuits on that fuse.

TROUBLESHOOTINGEQUIPMENT

VOLTMETER AND TEST LAMP

Use a test lamp or a vol tmeter on circuits without so lidstate un its and use a test

lamp to check for voltage. A test lamp is made up of a 12-vol t ligh t bu Ib with apair of leads attached. After g rounding one lead. touch the other lead to various

polrts along the c ircuit where voltage should be present .

When the bulb goes on, there is vo ltage at the point being tested .

CAUTION

A number of circuits Include solid-state modules, such as the Engine

Control Module(ECM), used with computer command ccntrol lnlectlen.

Voltage in these circuits should be tested only with a 10-megaohm or

higher Impedance digital multlmeter. Never use a test lamp on circuits

that contain solid state modules. Damage to the modules may result.

A voltmeter can be used in place of a test lamp. While a test lamp shows

whether the vo ltage is present or not, a vol tmeter indica tes how much voltageis present.

SELF-POWERED TEST LAMP AND OHMMETER

Use a selt-powered test lamp or an ohmmeter to check fo r continui ty.

The ohmmeter shows how much resistance there is between two points along

a ci rcuit. Low res istance means good continuity .

GGIOB




TROUBLESHOOTING INSTRUCTIONS (2) GI-9

CAUTION

Never use a self-powered test lamp on circui ts that contain solid statemodules. Damage to these modules may result.

An ohmmeter can be used in place of a self-powered test lamp.

The ohmmeter shows how much resistance there is between two points along a

c ircuit . Low res is tance means good continuity.

Circuits which include any sol id-sta te devices should be tested only with a

10-megaohm or higher impedance digital mul timeter. When measuring

resistance wi th a digi tal mu ltimeter , the batte ry negative te rminal shou ld be

disconnected. Otherwise, there may be incorrect readings. Diodes and

solid -state devices in a circu it can make an ohmmeter give a fal se reading.

To find out if a component is affecting a measurement, take one reading,

reverse the leads and take a second read ing.

If d if ferent the sol id-s tate device is affec ting the measurement.

JUMPER WIRE WITH FUSE

Use a jumper wire with a fuse to by-pass an open circuit.

A jumper wire is made up of an in-line fuse holder connected to a set of test leads.

This tool is ava ilable with small clamp connectors provid ing adaption to most con-

nectors without damage.

CAUTION

Do not use a fuse with a higher rating than the specified fuse that protects thecircui t being tested. Do not use this tool Inany situat ion to substi tute an Inputor output atthe solid-state control module, such as ECM,TCM, etc.

SHORT FINDER

A short finder is available to locate a short to ground. The short finder creates a

pu lsing magnetic field in the shorted circuit and shows you the location of the

shor t through body trim or sheet metal.

TROUBLESHOOTINGTEST

1.TESTING FOR VOLTAGE

This test measures voltage in a circuit. When testing for vo ltage at a con-

necto r, you do not have to separate the two ha lves of the connector. Instead,

p robe the connector from the back(backprobe). Always check both sides o f

the connector because dir t and corros ion between its contact surfaces can

cause electrical problems.

A. Connect one lead of a test lamp or voltmeter to a ground. If you are using

a vol tmeter, be sure it is the vo ltmeter 's negative test lead you have con-

nected to ground.

B. Connect the other lead of the test lamp or voltmeter to a selected test

pOint(connector or terminal).

C. ~ the test lamp glows, there is VOltage present. If you are using a

voltmeter, note the vo ltage reading . A loss o f more than 1 vol t from

specification indicates a problem.

GGI09




TROUBLESHOOTING INSTRUCTIONS (3) GI-10

IH OT A T A LL TIMES Ij--X--'DASH

I. 2 :FUSEI .BOX, ,, ,'--- -- ,

ON

,,....,OFF,,

SOLENOID

A. Disconnect the battery negat ive terminal.

B. Connect one lead of a self-powered test lamp or ohmmeter to one end of

the part of the circuit you wish to test. If you are using an ohmmeter, hold

the leads together and adjust the ohmmeter to read zero ohms.

C. Connect the other lead to the other end.D. If the self-power test lamp glows, there is continuity. If you are using an

ohmmeter, low or zero res is tance means good cont inui ty .

2. TESTING FOR CONTINUITY

3. TESTING FOR SHORT TO GROUND

A. Disconnect the battery negative terminal .

B. Connect one lead of a se lf-powered test lamp or an ohmmeter to the fuse

terminal on the load side.

C. Connect the other lead to a ground.

D. Beginning near the fuse block move the harness from side to side.

Continue this proceedure(about s ix inches apart) whi le watching theself-powered test lamp or ohmmeter.

E. When the self-powered test lamp g lows, or ohmmeter reg iste rs, there is a

short to a ground in the wiring near that point.

Battery

disconnected

FUSE BOX

(Fuse removed)

STOP

LAMPsWITCH

SELF·POWEREDTEST LAMP

OR

VOLTMETER

G

I _.....lfad~ olsconnecled

GGI10




GI-11ROUBLESHOOTING INSTRUCTIONS (4)

4. TESTING FOR A SHORT WITH A SHORT FINDER

A. Remove the blown fuse . Leave the battery connected.

B. Connect the short finder across the fuse tenninals.

C. Close all switches in series in the circuit that is being testing .

D. Turn on the short circuit locator. It sends pulses of current to the short.

This crea tes a pulsing magnetic fi eld around the wiring between the fuse

box and the short.

E. Beginning at the fuse box, slowly move the short finder along the circuit

wiring. The meter will show current pulses through sheet metal and body

trim. As long as the meter is between the fuse and the short, the needle

will move with each cur rent pulse. Once the meter is moved past the poin t

of the shor t, the need le will stop moving. Check around th is area to loca te

the cause of the short circuit .

rr~ M ove m eier

a lo ng w i re

N e ed le s to p sm o vi ng h e re

B_'Yd i s c o n n e c t e d

FUSE BOX( F us e r em ov e d)

Pulsingma!JIet ic

fi'~

~Shcrt to ground

SOLENOID

GGI11



WIRING REPAIR EDE"".2

WIRING REPAIR (1) GI-12

* REFERENCE SERVICE TOOLS

Tool Number Tool Name

TRKOOA Wiring Repai r Kit (Standard Kit)

TRK001 Wire Stripper Set

TRK002 Remover Tool Set

TRK003 Termina l Tension Gauge Set

TRK004 Cable Tie Set

TRK005 Shr ink Tube Set

TRK006 Jump Connector Kit(A)

TRK007-10 General Connector Kit(B-E)

TRK011 Terminal With Lead Wire Kit(F)

TRK012 Composition Kit(G)

TRK013 Lead Wire Set

TRK014 Carrying Case

TRK015 User's Guide & Parts Information

TRK016 Inner Box(Large)

TRK017 Inner Box(Small)

TRK018 Solder

.. For more details, re fe r to the User's guide & parts Information of the

Wir ing Repair Ki t (Pub. No. : OSG200208).

* Wiring Repair Kit

[Standard Kit (TRKOOA)]

TRK009

TRK003- TRK004TRK013- TRK017

TRK006

TRK002-1- TRK002-3

* Optional Items

TRK001 TRK002-4 TRK005 TRK018

Ie'

GGI12



WIRING REPAIR


REWORK PROCEDURE

1. Use of Wire stripper set (TRK001)

1) Disconnect the battery cable.

2) Choose the correct clamping slot for the wire and

strip o ff the wire coat.

® If the incorrect crimp ing slot is used, the te rminal

may be damaged and may not fit into the

connector.

2. Use of Remover tool set (TRK002)

~ Double tip type : Removal of double locking

malel female terminal f rom the connector .

3, Use of Terminal tension gauge set (TRK003)

1) Select the tension gauge tha t matches the female

terminal to be checked.

1) Remove the front or rear retainer (holder, stopper)

of the connector.

~ Flat tip type : Removal of single locking malelfemale tenninal from the connector.2) Insert a tension gauge into the female termina l

and check the terminal condit ion.

(as shown inthe photograph)

2) Ensure that the tip of the tool is inserted into the

gap between the e lastic arm of key and termina l.

3) Remove the terminal and check the terminal condition, if there is a

damaged, replace itw ith a new terminal.

® If the tension of female tenn inal is not tigh t

enough, remove it and replace the termina l and

wire assembly ( including seal).

GGI13



WIRING REPAIR


4. Use of Ring terminal (TRK012-4)

1) Strip off about 5mm of the wire coat at the end of

the wire.

2) Joint the stripped wire with ring te rminal and crimp

using wire stripper.

3) Put the shrink tube over the connection area and

shrink the tube using e lectrica l hot gun.

S. Use of Inline solder (TRK012-S) and Shrink tube set (TRKOOS)

1) Strip off about 5mm of the wire coat at the end of

the wires.

2) Insert each wire into the opposite ends of the

inline solder and crimp using wire str ipper.

3) Putthe shrink tube over the connection area and

shr ink the tube using electrical ho t gun.

®Shrink tube shou ld be securely wrapped around

the inl ine solder area.

GGI14

manual hyundai tucson

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