Published by Hyundai Motor company, june 2005 TG Chassis 1.A5HF1 (Delphi TMS) 2. ESP (Bosch 8)

Published by Hyundai Motor company, june 2005 TG – GRANDEUR AUTOMATIC TRANSAXLE HIVEC (A5GF1, A5HF1)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Variation A5HF1 : CM D-2.2L, TG λ-3.8L [A5HF1-2] A5GF1 : NF2.4L [Aug.05], TG δ-II 2.7L [Delphi PCM] Shift lock & ignition key interlock : Canada, USA, Aust., Japan, Taiwan Line-up AT - A5GF1 A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Appearance A5HF1(-2) A/T ASSY (D-2.2, λ-3.3D, 3.8D) A5GF1 A/T ASSY (μ-2.7D, 2.7LPI JSL) A5GF1 vs. A5HF1 AT - A5GF1 A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Accumulators 7 (1 VFS)6Solenoid valves (New design)Φ 260T/CON size (mm) 2Number of OWC 3Planetary carriers 4 Clutch 2 Brake 1 BandFrictional elements 7 or H-MATICGear shift position 430Length (mm) Torque (kg m) NF, TG, LZ, CMXG, GH, LZVehicle A5HF1F5A51Items Comparison Major specification

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Sub shift part is added - Increased number of pinion gears of overdrive planetary gear : 34 - Increased differential size (Size 56.1) - Case/Housing Newly designed and reinforced - Valve body with VFS - Flat torque converter New features AT - A5GF1 A5GF1 (Compared with F4A42)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose New features - Increased width by 2mm : output gear, differential drive gear - Single side plate : O/D clutch, 2 nd brake - Increased piston size of the reduction band - Increased bearing size by Φ5 mm AT - A5HF1 A5HF1 (Compared with F5A51) - Increased number of pinion gears of O/D planetary gear : 34 - Increased number of pinion gears of direct planetary gear : 34 - Case/Housing : Newly designed and reinforced - Flat torque converter (Higer torque capacity) - Increased differential size (Size 6.1 7) - Valve body with VFS (with reservoir)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose ) Features - Reinforced converter housing (More & thicker ribs) - New case design 2) Benefits - Increased binding force - Less bending vibration - Increased vehicle NVH performance TM case (A5GF1) Converter housing (A5HF1) New features Reinforced Case/Housing AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose O/D, DIR planetary gear F5A51 (Three pinions)F5A51 (Four pinions) Output gear (Increased width by 2mm) Differential gear (Increased width by 2mm) For durability Oil reservoir (A5HF1 only) New features AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Flat Torque converter Big sized ATMid sized AT AT Model Items Φ236 New (A5GF1) Φ260 Current (F5A51) 3725Max. torque (kgfm) Width (mm) Φ260Φ246Diameter New (A5HF1) Current (F4A42) New features AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Double sideSingle side SSP (Single Sided Plate) New features AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose SSP (Single Sided Plate) New features [Clutch disc] [Clutch plate] Up sidedown side Up side down side ItemsU/DO/DRevDir Material BWA D BWA BWA Usage4 DSP 1 SSP 6 23 Disc inner diameter Φ123 Φ152Φ87 Disc outer diameter Φ148 Φ166Φ122 Waves10EA DSP 6EA SSP - 11EA- Endplay (mm) 1.7±0.11.1±0.11.6±0.10.7±0.1 ItemsL/R2NDRED Material BWA BWA SD- 177-B Usage6 DSP 1 SSP 6 WRAP Disc inner diameter Φ161Φ152.8 Drum Φ134 Disc outer diameter Φ Waves10EA-- Endplay (mm) 1.65 ~ ~ AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS - Purpose : To improve fuel consumption. (1.8%) ComparisonPurpose Unnecessary high pressure Optimum pressure TPS Gear Line pressure (bar) Optimum line pressure Improved efficiency Lower fuel consumption Regulator valve Pump Line pressure Solenoid valve Regulator valve Pump Controlled pressure Line pressure Line pressure (bar) AT - A5HF1 New features

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Step gate type shift lever, A/T relay location AT relay AT - A5HF1 New features

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose PCM location (Delphi 3.3L, 3.8L) [TG 3.8L] [NF 3.3L] AT - A5HF1 New features

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Total 25 items Current data (Delphi PCM) AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Specification VFS valve 7.1 kgf/cm2 6.3 ~ 0kgf/cm2 (Normally high) 600 Hz 0 ~ 1.1 A 4.35 ± 0.35 Ω 1. Supply Pressure 2. Control Pressure 3. Frequency 4. Current range 5. Coil resistance VFSVFS - Current vs. Controlled line pressure 1,100 ~ ~ 10.5Bar(D-Range) 4.9 ~ 15.5Bar(R-Range) - Supply pressure : reducing pressure Control Supply Exhaust AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS Cooler pipe from the inside valve body VFS valve Pipe for VFS cooling Oil dam for cooling (A5HF1 only) AT - A5HF1 VFS valve

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Oil passage to use the reducing pressure for the source pressure of VFS The oil passage(channel) to supply the reducing pressure for the source pressure of VFS Application: - 4-speed A/T (F4A42-2) - 5-speed A/T (A5GF1, A5HF1) AT - A5HF1 VFS valve

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS(+) From AT relay P CM : VFS(-) VFS: (-) control type by TCM as same as others and the VFS power is supplied through A/T relay as conventional MELCO system. UD 2nd OD LR DCC VFS A/T relay UD(-) 2nd(-) OD(-) LR(-) DCC(-) VFS(-) NF, MG: Theta (4-speed AT) PCM (Siemens) Comparison (Siemens) AT – F4A42

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS output (Sport mode 1 st gear) AT – F4A42 Comparison (Siemens)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS(+) VFS(-) - VFS: (+) control type by TCM VFS power is not supplied through A/T relay but from PCM directly. - PWM solenoid valves : (-) control type by TCM UD 2nd OD LR DCC RED VFS A/T relay UD(-) 2nd(-) OD(-) LR(-) DCC(-) RED(-) VFS(+) NF, TG, VQ, LZ, CM: Lambda, Mu (5-speed) PCM (Delphi) Comparison (Delphi) AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Driving at sport mode 1 st gear VFS output waveform [VFS current] [Current data of VFS at S1] AT - A5HF1 Comparison (Delphi)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS output waveform At P/N range [VFS current] [Current data of VFS at P/N] AT - A5HF1 Comparison (Delphi)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose AT Tester with adapter cables for AT (F4A**, F4EL-K, AISIN) Pressure test (Preparation) AT – ALL

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Pressure sensor installation with AT Tester [AT Tester] [Pressure control box] [Pressure sensor & adapter] AT – ALL Pressure test (Preparation)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Pressure test (Preparation) Pressure sensor installation AT – ALL

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Line pressure control AT – ALL

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose UD clutch pressure control N D control VFS output waveform [VFS current] [Current data of VFS at D1, vehicle stop] AT – ALL

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose N D control UD pressure : 4.7 kg/cm 2 0 kg/cm 2 [ UD clutch pressure at N D control] ND1 (vehicle stop)N D 1.6 AT - A5HF1 UD clutch pressure control

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose [ UD clutch pressure vs. VFS output while driving at D/S] 10.5 kg/cm 2 Driving at D range D45/S D1/S1 D23/S23 UD pressure while shifting at D/S (Max. pressure : 10.5 kg/cm 2 ) 5.8 kg/cm 2 0 kg/cm 2 AT - A5HF1 UD clutch pressure control

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS output (short to GND) With VFS failure (N D control range) UD pressure : 5.8 kg/cm 2 0 kg/cm 2 ND1 (Vehicle stop)N D [ UD clutch pressure with VFS failure while N D control] AT - A5HF1 UD clutch pressure control

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose With VFS failure (Driving at D range) UD pressure : 10.5 kg/cm 2 D45 /S12 D123/S123 [ UD clutch pressure with VFS failure while driving at D/S] AT - A5HF1 UD clutch pressure control

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose N R control LR brake pressure control VFS output waveform [VFS current] [Current data of VFS at R] AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose LR pressure VFS output (duty 14%) [ LR brake pressure vs. VFS output while N R control ] 6.5 kg/cm 2 N R N R control 3.0 kg/cm 2 NR at idle 68% LR brake pressure control AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Driving at R VFS output (duty 14%) LR pressure_6.5 kg/cm 2 N R 3.0 kg/cm 2 NDriving at R 68% 17.0 kg/cm 2 [ LR brake pressure vs. VFS output while driving at R] LR brake pressure control AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose With VFS failure (N R) LR pressure at R : 6.5 kg/cm 2 [ LR brake pressure with VFS failure at N R] LR brake pressure control N RNDriving at R LR pressure at N : 9.0 kg/cm 2 AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose With VFS failure (Driving at R) At N : 9.0 kg/cm 2 N Driving at R R (Driving) : 17.5 kg/cm 2 [ LR brake pressure with VFS failure while driving at R ] LR brake pressure control ND R (Static): 6.5 kg/cm 2 AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose AT control relay UD SOLV/V OD SOLV/V LR SOLV/V DCC SOLV/V K-line RED SOLV/V 2ND SOLV/V VFS Input speed sensor IG ON & GND Inhibitor switch Oil temperature sensor Brake switch PCMPCM PCMPCM CAN Inputs & Outputs Output speed sensor AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Reset function Purpose : when replace an AT transaxle, pressure data of the AT memorized in the PCM needs to be reset to put in the new pressure data. After PCM resetting, proper PCM learning procedure should be followed. AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose ND, NR Learning (1)The learning zone for Static Shift is decided depending on the ATF temperature (- 5~120 ) and engine speed < 1000rpm. (2)After N R or N D shift, select N range for 4sec or more and repeat several times) (1)Remain the TPS 1.6±0.15V (Throttle ) and shift up D1 D5 several times (around 5 times) (2)Perform the procedure (1) at TPS > 2.5V & TPS < 1.2V Power On Down Shift Learning Reset function Preparation : Initialize ETS and warm up the engine at P idle for TPS learning. AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose [Current data while driving : manual shift 2 nd gear 3 rd gear at Sports mode] 2 nd gear [P0717 is displaced when input speed sensor is open or short to GND] Failsafe Input speed sensor failure (P0717) 3 rd gear AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose DTC Description P0717 (PG-A open or short) The TCM sets this code if a pulse-signal is not detected, from the input speed sensor, when the vehicle is running faster than 30 km/h. The Fail-Safe function will be set by the TCM if this code is detected. AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Failsafe Output speed sensor failure (P0722) [P0722 is displaced when output speed sensor is open or short to GND] [Before the failure detected : PCM calculates the output speed from the input speed after 3000rpm of input speed. Before 3000rpm, PG- B is 0 rpm and gear is fixed to 1 st gear] Fake value [Current data while driving : manual shift 2 nd gear 3 rd gear at Sports mode ] AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose DTC Description P0722 (PG-B open or short) The TCM sets this code if the calculated value of the pulse-signal is noticeably different from the value calculated, using the Vehicle Speed Sensor output, when the vehicle is running faster than 30 km/h. The TCM will initiate the fail safe function if this code is detected. AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose The switch control signal will be shared with Engine Coolant Temp Sensor. 2. More acurate high temperature detection 3.R1 = 3.6 K, R2 = TR On : 348 Ω, Off : ( ) kΩ Oil temperature sensor Temp(˚C) Resistance(k ) ± ± Temp vs. Resistance AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose PCM controls the TR according to the temperature condition. 1) ECT 50 ˚C, OTS 80 ˚C : TR OFF ( ) kΩ 2) ECT 50 ˚C, OTS 80 ˚C : TR ON OFF (Pulse) 3) ECT 50 ˚C, OTS 80 ˚C : TR ON OFF (Pulse) 4) ECT 50 ˚C, OTS 80 ˚C : TR ON 348 Ω * ECT : Engine Coolant Temperature, OTS : Oil Temperature Sensor TR ON (for ECT) TR OFF (for OTS) TR ON (for OTS) TR OFF (for ECT) AT - A5HF1 Oil temperature sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose CH A: engine coolant sensor (44 ) CH B: AT Oil Temp sensor (49 ) CH A: engine coolant sensor (54 ) CH B: A/T Oil Temp sensor (60 ) High side for ECT (TR ON) Low side for OTS : (TR OFF) Ch A : ECT Ch B : OTS Output waveform AT - A5HF1 Oil temperature sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose When the oil temperature sensor is short to Ground, the trouble is detected immediately and P0712 is displayed. Hi-scan service data is fixed 214 º C however the replaced oil temperature by PCM is 85 ºC. Failsafe Oil temperature sensor short to GND (P0712) No VFS control : Maximum line pressure AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose P0712 (Oil temperature sensor Short to ground) This DTC code is set when the ATF temperature output voltage is lower than a value generated by thermistor resistance, in a normal operating range, for approximately 1 second or longer. The TCM regards the ATF temperature as fixed at a value of 85°C DTC Description AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Oil temperature sensor open (0713) When the oil temperature sensor is open, the trouble is not detected immediately and ND, NR, PR shift shock is severe. The trouble will be detected around 5 minutes after driving. Hi-scan data is fixed -40 º C however the replaced oil temperature by PCM is 85 ºC. Failsafe AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose DTC Description P0713 (Oil temperature sensor Open or short to B+) This DTC code is set when the ATF temperature output voltage is higher than a value generated by thermistor resistance, in a normal operating range, for an extended period of time. The TCM regards the ATF temperature as fixed at a value of 85°C. AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose DTC Description P0711 (Oil temperature sensor rationality check, OBD area only) 1)Rationality error - 7hr after key-off and starts engine, - Temperature difference between oil temperature and coolant temperature minutes after engine running 2)Abnormal change of oil temperature - Oil temperature change 20 for 1 second after engine starts 3)Stuck error - Oil temperature change for 10 minutes after engine running 0.5 4)Warm-up error - Engine rpm 1000, - Ouput speed 1000, - Oil temperature

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose AT relay VFS 16 V 33 V Main duty signal AT relay control signal Feedback PWM solenoid valve VFS PWM signal VFS signal Sensing Driver + - PCM B76 A20 A60 B22, B3, B45, B42, B44, B43 B75 B59 Main relay driver Feedback 20A 10A AT relay AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose P0885 (AT relay ) - A20 circuit short to GND for 5 seconds after IG on or engine running - 10A fuse for B76 is open 2.P0890 (AT relay voltage low) - A60 circuit short to GND for 2 seconds - AT relay fuse (20A) is open 3.P0891 (AT relay voltage high) - A60 circuit voltage 20V for 2 seconds (for detecting surge voltage) Failsafe : AT relay off 3 rd gear fixed at D DTC Description AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Failsafe AT relay voltage low (P0890) [Current data while driving at D : - AT relay OFF 3 rd gear fixed, - Pressure sol. OFF Max. line pressure] [P0890 is displayed 20A fuse for AT relay is open] AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose PWM solenoid valves : UD, OD, LR, 2 nd, RED, DCCSV 2. Normally high type : duty 100% pressure release, duty 0% Pressure apply 3. Operating frequency : Hz (DCCSV: 30.64HZ), 4. Resistance : 3.2±0.3 Ω PWM solenoid valves A/T relay PWM solenoid PWM control signal Sensing AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Duty control PWM Solenoid output (UD solenoid valve) Duty 100% (solenoid ON) Duty 0% (solenoid OFF) ON AT - A5HF1 PWM solenoid valves

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Current data of solenoid duty AT - A5HF1 PWM solenoid valves

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Current data of solenoid duty AT - A5HF1 PWM solenoid valves

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Current data of DCCSV [DCCSV OFF condition][DCCSV ON condition] Damper control : solenoid 100% ON (Damper clutch slip should be 0) Damper clutch operation : D/S3,4,5 (TG Lamda 3.3L) -29 oil temperature when IG is on, 2 nd gear fix Oil temperature (Gradient 7% or more) : High temperature mode 2 nd 3 rd gear (2 nd gear & 3 rd gear range extended, 2 nd gear lock-up available) AT - A5HF1 PWM solenoid valves

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose rd 4 th 5 th gear 100 % [Damper clutch is disengaged while shifting] 2 nd 3 rd gear 94.5 % 0 % [DCCSV duty is gradually increasing] Current data of DCCSV AT - A5HF1 PWM solenoid valves

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose When A PWM solenoid valve (except TCC solenoid) is open or short the failure is detected immediately. And the PCM turns the AT relay off resulting in 3 rd gear fixed at D range (including Sports mode). Failsafe PWM solenoid open or short When A PWM solenoid valve (except TCC solenoid) is open or short the failure is detected immediately. And the PCM turns the AT relay off resulting in 3 rd gear fixed at D range (including Sports mode). Variable line pressure control is inhibited and maximum line pressure is generated. AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose VFS (Variable Force Solenoid) B/T R1(Sense resistor) VFS PWM signal VFS Enable signal Sensing signal VFS Driver Sensing signal 1. Normally high type : duty 100% pressure release, duty 0% Pressure apply (6.3 kgf/cm 2 ) 2. Operating frequency : 600 Hz 3. Current range : 0 ~1.1A 4. Resistance : 4.35±0.35 Ω AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose P0748 is detected as soon as VFS circuit is open or short. When the VFS fails, variable pressure control is not available but AT relay is controlled normally. (Max. pressure) So PWM solenoid valves are operated as scheduled without shift shock while shifting up and down. Failsafe VFS solenoid AT - A5HF1

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Failsafe Inhibitor switch circuit open (D range signal) When the D range signal is open, PCM controls the vehicle according to the previous range signal. After engine starts shift lever moves P-R-N-D in sequence, D range control will be substituted by N range signal. UD clutch pressure is not applied so vehicle cannot move. Sports mode also cannot be available because the power supplied via D range terminal of inhibitor switch. AT - A5HF1

Published by Hyundai Motor company, june 2005 BOSCH AND ESP ( Electronic Stability Program) Granduer (TG)

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Variation Line-up (BOSCH 8 ABS/ESP) * ABS : Optional item for GL model (General area, Aust.) TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Cmponents of ESP system TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Variant coding Perform the variant coding if there is a ESP OFF W/L on with a C1702 (Variant Coding Error) after replacing a ECM,TCM or ESPCM. TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Construction Hydraulic control unit Solenoid Valve (x12) Valve Coil (x12) Low Pressure Chamber Piston (x2) Pump (x2) Motor Pressure Sensor ESPCM TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Prevent a pressure overshoot or undershoot Control range decrease - Noise : Pulse-Up Noise decrease - Enhanced Pedal Feeling On/Off LFC Slip LFC Control Range On/Off Control Range Effect of LFC (Linear Flow Control) LFC (Linear Flow Control) TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Actuation test PWM control ON/OFF control TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Hydraulic control unit TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose HECU Pressure sensor Operating condition Hydraulic brake assist - over 30 bar - over 2200 bar/sec - over 20 km/h TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Inputs and Outputs Pressure Sensor (HCU Built-in type) TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Active wheel speed sensor - Type: Hall Effect - Output signal: Digital (Open Collector Type circuit integrated) - Good characteristics against temperature variation and noise - Low RPM Detection: 0 RPM can be detected - Air gap sensitivity: stable output pulse against air-gap change -Supplying power: DC 12V TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Inspection Teeth: 48 12VGND Battery R(100Ω) Oscilloscope V high = 1.2~1.7V V low = 0.6~0.8V TG ESP Bosch 8 Active wheel speed sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose YAW Rate and Lateral G sensor Appearance TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Sensor specification a. Yaw Rate Sensor Specification Measuring Range : ±100˚/s Resolution : 0.3˚/s Output Voltage Range : 0.5 ~ 4.5V Sensitivity : 18 mV / (°/s) b. Lateral G (Acceleration) Sensor Specification Measuring Range : ±1.8 g (±1.5G) Resolution : 0,005 g Output Voltage Range : 0.5 ~ 4.5 V Sensitivity : 1V/g TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Pin layout [Sensor connector - Male side] TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Sensor Output [Pin1- Reference voltage of the sensor][Pin2- Bite : for self test] IG ON TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Sensor Output [Pin4 - Output of Yaw Rate][Pin3 - sensor power] TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Sensor Output [Pin5 - Lateral G sensor output][Lateral G sensor output: 90˚ to the right] TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Sensor self-test (Yaw rate sensor) Pin2 - Bite Pin 4- Yaw rate sensor output TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Sensor self-test (Lateral G sensor) Pin2 - Bite Pin 5- Lateral G sensor output TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Current data & DTC TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose C1282 (Reference voltage/Yaw/Lateral G Sensor short to GND) Current data & DTC TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose C1283 (BITE shoft to GND) Current data & DTC TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose [When the BITE(Pin2) short to GND] Current data & DTC [When the BITE is normal] Lateral G sensor output TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Current data & DTC Yaw rate sensor output [When the BITE(Pin2) short to GND] [When the BITE is normal] 2.5V without wave pattern TG ESP Bosch 8 YAW Rate and Lateral G sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Steering angle sensor Appearance Maker : RUF (Germany) Installation : Steering wheel TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Hi-scan data TG ESP Bosch 8 Steering angle sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Steering angle calibration Suspension analysis for steering angle calibration or wheel in straight- ahead position. A prolonged straight- ahead drive can also be used during calibration to determine the steering wheel center position. Calibration of the wheel angle sensor in straight-ahead position. (An incorrect calibration will set a fault code in the fault code memory.) ±5° or less TG ESP Bosch 8 Steering angle sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Steering angle calibration - Steering angle sensor calibration : After SAS replacement or clock spring replacement TG ESP Bosch 8 Steering angle sensor

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Pressure sensor Operating Voltage : 5± 0.25 V Output voltage : 10% ~ 90% V pwr Operating Pressure : 0 ~ 200 bar Response time : Max. 10msec Operational Temp. : - 40 ~ 125 Specification TG ESP Bosch 8

© HMC & KMC reserves all rights of disposal such as copying and passing on to third parties. This book should be used for the training purpose Warning lamp control a)EBD W/L control b)ABS W/L control c)TCS/ESP OFF W/L control d)TCS/ESP Function Lamp control a) b) c) d) TG ESP Bosch 8