Quality Problem & Trouble Shooting

Subject Models Condition

International A/S & Parts Team 2001.08.10

Noise from alternator in CD operating Chairman

In audio operating, abnormal peak noise sounds from speaker due to alternator revolution.

Main cause
Dsp wire which is linked to the engine room fuse No.33, is too long, so this wire is exposed to any electrical noise signal.

Improvement
The DSP wire route is changed to connect it to trunk fuse No.41. In-line date : Apr.15,2001 - VIN 17254

Rework procedure
1. Disconnect the Battery (-) terminal 2. Disconnect 16 pin connector of DSP 3. Take out No 1 pin from the connector, then wrap up the pin to deelectric : No1 pin :0.5 sq,BlW 4. Fix the modification wire to the trunk fuse box like picture. 5. Inset the end of the wire to the No.1 position of the DSP connector 6. Replace the Fue 30A (No 53) with 7.5A 7. Connect the battery (-) terminal

Quality Problem & Trouble Shooting

Subject Models

International A/S & Parts Team 2001.08.10

Noise from alternator in CD operating Chairman

Separate DSP connector

Rework wire

Fix point

Operation code and Labor time

Operation code Work discription Labor time

5509990

Audio wire modification

0.3 M/H

Confirm If not solved this noise, check belows 1. Check the condensor into junction box under the seat 2. Check the condensor in the engine room C.E box 3. Finally replace the alternator

Shifting problem of transmission

Oct.17,2001 1. Model : Chairman 600S

2. Phenomenon : Occur the shift delay or shift shock on the driving

3. Cause Different (or unmatching) type between engine ECU and TCU Installed TCU is not coded

4. Failure code descriptions on the scan-tool diagnosis In case of 'VDO 32' engine ECU and 'Bosch' type TCU Vehicle condition On the scan-tool diagnosis Diagnosis point Failure code Engine ECU side TCU is not coded Other equipment TCU side Engine ECU side TCU is nomalcy TCU side ABS/ASR side 26 E36/E37/E39 31 CAN communication failure : TCU CAN : EMS information failure EMS (engine) failure 26 Description CAN communication failure : TCU Normalcy All values from engine ECU are indicated zero On the sensor signal value diagnosis

5. Work procedure Check the type of vehicle and engine (ECU) Install and coding the TCU that is match for the vehicle and engine (ECU) type

6. Part number of TCU and coding parameter by engine ECU type Engine ECU type Bosch 32 VDO 32/28 VDO 23 Part number of TCU 020 545 24 32 020 545 25 32 36610 11000 (BTRA) TCU is not coded case. Coding parameter for TCU e03eA0y07 e03eA0y09 e03eA0y02 or e03eA0y13 e03eA0yFF

Quality Problem & Trouble Shooting

Subject Models Condition

International A/S & Parts Team 2001.08.10

Noise and vibration when to steer the wheel Chairman 400S

Noise and vibration happen when to steer the wheel toward full right or left hand

Main cause
Only belt tendioner was installed on the CM400 model limitedly. Now the belt shober is installed together with the tensioner.

Rework
If the above problem occurs, the present belt tensioner and shober
Defect Part number 111 200 12 70 Present part number Tensioner : 111 200 07 70 shober : 111 200 02 14

Caution When to tighten the belt tensioner pulley, do not tighten over torque. If tighten too much, interference occurs between the tensioner fixing point and
mooving part.

Quality Problem & Trouble Shooting

Subject Models Phenomenon
- The ABS/ABD warning lamp always on

International A/S & Parts Team

ABS/ABD WARNING LAMP ON CHAIRMAN

Main Cause
- The Switch a-stop lamp is damaged. ; The stop lamp switch is improper connection becasue the terminal of switch inside is broken.

stop lamp switch

Work procedure
- Replace it with new one.

Improvement history :
- The thickness of terminal which is inside of switch is increased. ; 0.11 -> 0.2mm - Applied date : Apr.14,2000. - Applied VIN No. : 10300~

Quality Problem & Trouble Shooting

Subject Models 1. Service flow
Function of rain sensing Chairman

International A/S & Parts Team 2001.08.10

Check to install condition for windshield glass and coupler

Check to power-up function

Check to instant wipe function

Check to wiper function

Check to high speed for wiper

Check to irregular acting

Check to self diagnostic function

1) Check to install condition for windshield glass and coupler - Check to abnormal wear, scratch and defection with windshield portion into the sensing area. - Check to wear status of glass to using self diagnostic function. - Check to coupler. 2) Function of power-up - Wiper act 1 time when the ignition switch turn on during auto mode ( or the wiper switch turn auto mode from off position during ignition on) then remove the function after 5 minutes. : Recognized to driver whether is the wiper function acting. - Wiper work when it's rain. (wiper speed depend on rain rate) - Wiper work during 5 minutes after stop rain. - If the function doesn't work, check to unit 8 and low wiper unit. (place fuse box in engine room). 3) Function of instant wipe. - The wiper works 1time when knob of combi-switch turns each 1stage. It's recognized raining. - If the function doesn't work, check to variable resistor of terminal 5. (1stage("S"):50, 2stage:37.5, 3stage:25, 4stage:12.5,5stage("F"):0) 4) Function of washer & wiper. - The wiper work and spread washer water when you press the washer switch. - If the function fault, check to terminal 6. * Function of MTST : When you press washer switch short time(0.2~0.6sec), the washer water spread and the wiper work 1time. 5) Check to max. speed operation. - The wiper work max. speed when it's heavy rain. - If the function fault, check to terminal no.1(low speed) and no. 2(high speed). 6) Irregular operation. - Check to separate sensor, and install condition of sensor cover. - Check to customer know how to use the combi switch. - Check to wear of wiper blade. 7) Function of self diagnostic. - Place the auto position of combi switch, turn 1step the knob of variable resistor from fast position to slow position. : If the wiper operate, the windshield glass occur wear or scratch. When sensing is problem, replace the windshield, When sensing is problem, replace the windshield glass, or check to sensor and installation of coupler. - After above step, turn more 1step the knob of variable resistor. : When the wiper operate, replace the sensor.

urn 1step the knob of variable resistor from fast position to slow position. s occur wear or scratch. When sensing is problem, replace the windshield,

Quality Problem & Trouble Shooting

Subject Models 1. Condition
1) Occur the wind noise at upper side of door wind glass during the driving. - Bias the wind glass towards front side when the glass go up. - The wind glass insert that the glass bias when the glass gone up. 2) Check process. - Attached the paper tape with wind glass out side and run rubber

International A/S & Parts Team 2001.08.10

Service procedure of wind noise Chairman

2. Cause
- There are clearance between the glass run and carrier plate.

3. Check to regulator
1) Adjust of regulator
- Loose the mounting bolt of regulator. (upper 2 points, lower 2 points) - Tight the mounting bolt of regulator while the regulator press direction of door latch mounting. - Check to whether the glass bias during going up and down.

2) Check to regulator
- Check to clearance of carrier plate when the fixed piece separate from wind glass. (Available to mounting condition of wind glass)

* Figure
Nut 2EA (upper side)

Carrier plate Nut 2EA (low side)

Occur of noise

4. Others
- The wind noise occurs a variety of cause. After accurate investigation, treat service work.

Quality Problem & Trouble Shooting

Subject Models 1. Condition
- Fault parts when fuse shortage : Fault of truck opening Fault of fuel door opening Fault of center door lock switch of driver side

International A/S & Parts Team 2001.08.10

Intermittent shortage of trunk fuse Chairman

2. Fault position

Interference of wiring.

("B" pillar-RH side, wiring connector of rear door)

3. Cause
- Interfere with mounting bolt of door checker and wiring of terminal no 2 at C371 connector.

4. Work procedure
- Tape work by insulated tape at shortage portion. - Exchange connector and wiring. - Attached the sponge at mounting bolt end portion of checker.