TroubleShooting(Chairman)

8/12/2019 TroubleShooting(Chairman)

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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 toany electrical noise signal.

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

Rework rocedure1. Disconnect the Battery (-) terminal2. Disconnect 16 pin connector of DSP3. Take out No 1 pin from the connector, then wrap up the pin to deelectric : No1 pin :0.5 sq,BlW4. 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 7.5A7. Connect the battery (-) terminal

International A/S & PartsTeam

2001.08.10

Condition

Quality Problem & Trouble Shooting

Subject

Models

Noise from alternator in CD operating

Chairman


2/11

Operation code and Labor time

Audio wire modification

ConfirmIf not solved this noise, check belows1. Check the condensor into junction box under the seat2. Check the condensor in the engine room C.E box3. Finally replace the alternator


2001.08.10


Subject

Models

Noise from alternator in CD operating

Chairman

5509990

Operation code Work discription Labor time

0.3 M/H

Separate DSP connector

Rework wire

Fix point


3/11

Shifting problem of transmissionOct.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

Failure code Description

Engine ECU side 26CAN communication failure : TCU

Other equipment - Normalcy

TCU sideAll values from engine ECU are indicated zero

Engine ECU side 26CAN communication

failure : TCU

TCU side E36/E37/E39CAN : EMS information failure

ABS/ASR side 31 EMS (engine) failure

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

Vehiclecondition

Diagnosis pointOn the scan-tool diagnosis On the sensor signal

value diagnosis

TCU is not coded

TCU is nomalcy


4/11

Condition

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.

ReworkIf the above problem occurs, the present belt tensioner and shober

CautionWhen to tighten the belt tensioner pulley, do not tighten over torque.

If ti hten too much, interference occurs between the tensioner fixin oint andmooving part.

Present part number Defect Part number Tensioner : 111 200 07 70shober : 111 200 02 14

111 200 12 70


2001.08.10


Subject

Models

Noise and vibration when to steer the wheel

Chairman 400S


5/11

- The ABS/ABD warning lamp always on

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

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~

International A/S & Parts Team

Phenomenon

Main Cause


Subject

Models

ABS/ABD WARNING LAMP ON

CHAIRMAN

stop lamp switch


6/11

1. Service flow

Models Chairman

Quality Problem & Trouble ShootingInternational A/S & Parts

Team

2001.08.10

Subject Function of rain sensing

Check to power-up function

Check to install condition for windshield glass and coupler

Check to instant wipe function

Check to wiper function

Check to high speed for wiper

Check to irregular acting

Check to self diagnostic function


7/11

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 positi : If the wiper operate, the windshield glass occur wear or scratch. When sensing is problem, replace the winds 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.


8/11


9/11

on.hield,


10/11

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

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

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

Models Chairman


Team

2001.08.10

Subject Service procedure of wind noise

Occur of noise

Nut 2EA(upper side)

Nut 2EA(low side)

Carrier plate


11/11

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

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.

Models Chairman


Team

2001.08.10

Subject Intermittent shortage of trunk fuse

TroubleShooting(Chairman)

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