jm introduction 20040205

JM - Introduction

1 Chonan Technical Service Training Center

JM (TUCSON) Service

Training Guide

Published by

Chonan Technical Service Training Center

JM - Introduction


FOREWORD

This service-training booklet has been prepared for service technicians of authorized Hyundai distributor to familiarize them with JM (TUCSON). It is our intention to increase the level of skill and knowledge of service personnel to enable effective and efficient problem diagnosis and repair.

February, 2004 Printed in Korea

Published by Chonan Technical Service Training Center

copyright by Hyundai Motor Company

All right reserved.

Chonan Technical Service Training Center

http://training.hmc.co.kr

[email protected]

JM - Introduction


Contents

JM - Introduction


1. Introduction

1.1 General JM car was developed as a concept of small sized SUV (Sports Utility Vehicle) based on the same

platform with XD Elantra. Its size is smaller than current SM (Santa Fe) but the exterior styling is a

little bit similar with it. The vehicle name of JM is a “TUCSON”. It is the city name of USA in Arizona

State. This city is located in the desert area and has a Spanish culture. Also the old western styled

building and the most modern tradition coexists together. This name represents the crossover image

and the dynamic feeling of JM car as a SUV.

- SUV unique features

Roof Rack Privacy Glass

(Rear Door + QTR + Backlite Glass)

Flip-up Tail Gate Glass

Large Tire & Wheel

215/16 inch

235/16 inch (Option)

Side Garnish

Wheel Arch Molding

Underbody

Skid Plate

Electronic controlled

4WD Function

195mm

JM - Introduction


- Vehicle concept

All New Sophisticated Concept

SEDAN

SUV

JM MPV

Market Needs &

Trend Line-up & Brand

Image

Car Ride & Handling

- Based on XD Platform

Eng, TM, Steering, Suspension

SUV Exterior Styling

- Simple but Strong

- Large Tire & Ground Clearance

Torque on Demand Type 4WD

- Highly Advanced 4WD System

MPV Space Utility

- Flexible Seat Mechanism

- Extra-Wide Cargo Room

JM - Introduction


- Interior

Crash Pad & Storage

Mild

Rugged

On-Road Off-Rood

Wrangler

Freelander RAV4

Explorer

SM

Vitara

HP

CR-V

M-Class

X5

JM

Tray under

Bottle Holder

& Map Pocket

Lower Crash Pad Tray

Cup Holder

Tray under

Fascia Panel Deluxe

console

JM - Introduction


Luggage Area

- Comparison

- Safety

Washable Luggage Floor

Luggage Tray Luggage Net Export Product

Height Adjustable

Seatback Same Plastics

Front - Walk-Through

- Seat Armrest (Driver)

- Seat Under tray (Passenger)

- Seatback Folding to Table Form (Passenger)

Rear - Full Flat

- Center Armrest

- Forward Folding and Dive to Floor for

luggage Area

Walk-Through Full-Flat

Rear Center Armrest Rear Seats Folding & Dive

to The Floor

- Meet All Regulation

- Rear Center 3 Point Seat Belt & Headrest

- ABS & TCS

- ESP

- Dual Air Bags

- Side Air Bags and Air Curtain

Exterior

Honda Toyota Hyundai

205 / 70 R15 215 / 70 R16 225 / 70 R16 215 / 65 R16

235 / 60 R16

Tire

1,535 1,505 1,540 0 1,540 Wheel Tread

2,619 2,489 2,620 +10 2,630 Wheel Base

JM

Differe

nce

(-)

1,681 1,679 1,675 +5 1,680 Overall Height

1,783 1,735 1,820 -25 1,795 Overall Width

4,536 4,221 4,500 -175 4,325 Overall Length

CR-V RAV4 Santa Fe

Items

JM - Introduction


- Convenience

- Product value

* Hiden ‘In Belt’ type of door trim was applied.

- Power Window & Central Door Lock

- Keyless Entry

- Electric Sunroof & Overhead Console

- Power Outlet (2EA)

- Trip Computer

- Auto Light Control

- Full Auto Air Con

- Air Quality Control System

- Various Audio

(Radio, Cassette, CD, MP3)

Exposed

‘In Belt’

Hiden

JM - Introduction


For better exterior view, lower weight and cost.

* Non-housing type outside door handle was applied.

For better exterior view and lower cost.

* Flip-up type tailgate

Same system in Santa Fe.

Housing type Non-housing type

JM: Hidden wire SM: Exposed wire for glass heating

JM - Introduction


* De-icer wiper * Rear seat

* Mounting

* Propeller shaft

For lower NVH.

* Hub bearing

For lower noise.

: Dust cover added.

, : Reduced gap to prevent the inlet

of foreign materials.

Increased bearing capacity:

(XD Carry over SM Carry over)

Reclining Fold & Dive

FRT

ROLL

TM

MTG

ENG

MTG.

RR

ROLL

Universal joint

Rubber Coupling

Center bearing rubber

Bending absorber (inside of tube)

JM - Introduction


* Electrical contact connector

To improve the exterior view of the flip-up type

tailgate wire, the electrical contact type

connector was applied instead of the curl wire.

* 4-Ring body structure for higher strength

* Double box structure for 4WD device

* Door beam Layout

The optimized door beam layout

for the enhanced strength against

the side impact.

* Swollen face on the floor

To absorb the vibration generated from the floor,

Ring #1

Ring #2 Ring #3

Ring #4

Propeller shaft Inside

Outside

4WD P/Shaft

Front Rear

JM - Introduction


the swollen face was applied on the floor.

* One more hood-fixing guide

* EGR cooler (D-2.0 C/Rail engine only)

Two hood-fixing guides for easier

repair on engine room area.

EGR Cooler

EGR valve

Cooled exhaust gas

Exhaust manifold

Exhaust gas (Hot)

Coolant IN

Coolant OUT

JM - Introduction


1.2 Technical Highlights - Engine

β 2.0 I4 GSL Engine

- 145 ps/6,000 rpm

- 19.0 kg·m/4,000 rpm

D 2.0 DSL Engine (Europe)

- 111 ps/4,000 rpm

- 25.0 kg·m/2,000 rpm

δ 2.7 V6 GSL Engine

- 175 ps/6,000 rpm

- 24.7 kg·m/4,000 rpm

CR-V

- 2.0 Gas (150 ps)

- No DSL Engine

RAV4

- 2.0 Gas (150 ps)

- 2.0 DSL (116 ps)

- No Premium Engine

JM - Introduction


- Manual Transaxle

5-Speed Manual Transaxle

Drive train Variant

M5GF1 model:

- Applied on EF, FO car

- Triple synchronizer cone was adopted on the

1st,2nd synchronier gear to improve shift feeling

and reduce shifting force.

- Keyless type:

F4A42

MT

4WD

AT

β-2.0 I4 Gas

2WD

AT MT

-

F4A42

M5GF1

-

M5GF1

- δ-2.7 V6 Gas

F4A42 F4A42 M5GF1 M5GF1 D-2.0 DSL

Triple synchronizer

3 friction faces

Sleeve 2nd gear

1st gear

JM - Introduction


Key and Ω type spring were replaced with the

- Clutch: Hydraulic ‘Push’ type

- SMF (Single Mass Flywheel) was applied.

- 4WD system

4WD Locking Button on Fascia Panel

Constant 2WD/4WD or Auto Control

- 2WD: Front Wheel Drive

- 4WD: Electronically Controlled All Wheel Drive

- Normal driving with constant speed:

Driven with ‘FF2WD’.

ECM

Front Axle

Rear Axle

Transfer Case

Transfer case Rear axle & Coupling

4WD ECM

JM - Introduction


- Sudden vehicle starting, low friction

road driving:

Driven with 4WD automatically by

ECM control.

- Better fuel consumption and faster

response than mechanical type.

- Automatic Transaxle

Applied model: HIVEC F4A42

The shift lock and key lock cable were applied. (Only N/A, Aust., Taiwan, Japan)

TCM Location

* For LHD * For RHD

* Sports mode 4-speed front driving

* A/T relay DTC code was changed.

ECM (PCM)

TCM : δ-2.7 / D-2.0

ECU(PCECM (PCM)

TCM: δ-2.7 / D-2.0

RH Side inner panel LH Side inner panel

F4A42 for 4WD transfer

Cable end

Washer Spring

Shift lock cable

P

Key lock cable

JM - Introduction


- Old: P1723 (A/T relay open or short)

- New: P0885 (A/T relay open or short)

- Application: From JM vehicle

- Objective: To satisfy the renewed regulation

of North America.

* It is planned to adopt ‘F4A51’ in D-2.0 VGT.

- ESP System

* Objectives:

- For more stable handling performance

- To prevent the oversteering and understeering effect

- O X Lateral G sensor

- O O Yaw rate sensor

- O O Steering angle sensor

Master cylinder O O Pressure sensor

Same shape

ESP 2WD ESP 4WD ESP H/UNIT

2WD/4WD

FRT: Same RR: Diff.

ACTIVE ACTIVE Wheel speed sensor

Remarks 4WD ESP 2WD ESP

HECU

Wheel speed sensor

Steering angle sensor

Yaw rate sensor &

Lateral G sensor

Mando MGH-25 ESP HECU

JM - Introduction


- SRS System

Side body deformation Floor deformation

* Depowered airbag system (Except North America)

ACU (Airbag Control Unit): Bosch, AB8E Model

- DAB, PAB, SAB, CAB

- Single threshold without buckle switch

- TRW (Germany)’s CAB (Curtain Airbag) was applied

to satisfy the regulation (Euro NCAP Car-to-Pole)

- FIS (Frontal impact sensor) was applied.

- PPD (Passenger presence detection) sensor removed.

- CAB and SAB are deployed together always.

* Advanced airbag system (North America only)

- Delphi (USA) system to satisfy the new regulation of FMVSS 208 (USA)

PAB Module

(2stage)

PPD sensor Seat track position

sensor

DAB Module Buckle switch

Telltale lamp PASSENGER AIRBAG OFF

Pretensioner

sensor

Front impact

sensor

JM - Introduction


- Body Electrical

* Trip computer

: DTE (Distance to empty), Average fuel consumption

Odometer

: Trip computer switch is located on the cluster

housing.

* 20pin diagnosis connector in engine room

A D

B E G I K M P S

R O

F C H J L N Q T

Chassis K-Line (Factory air bleeding) H

- G

Body K-Line F

- E

- D

- C

B+ B

B+ (HMC only) A

Terminal

GND R

- Q

- P

MELCO TCM Reprogramming Comm. O

IG Switch (Factory air bleeding) N

MELCO TCM Reprogramming power M

- L

P/T K-Line K

Terminal

ECM

TCM

Immo. Control module

20 pin (K)

OBD (7)

20 pin (O)

JM - Introduction


* RCT connector was removed and this 20 pin connector is used for TCM reprogramming.

- Immobilizer system

* D-2.0 C/Rail: Bosch SMARTA

* Delta 2.7, Beta 2.0: Stand-alone

- Operating voltage range: DC 6 ~ 16V

- Operating temperature range: -40 ~+85

- Storage temperature range: -40 ~+85

- Current consumption: 100mA(min) 200mA(max)

- Radio Frequency: 125kHz

JM - Introduction


- Suspension

* Front: Macpherson with coil spring

- The improved design of lower arm

was applied to reduce the ‘shimmy’

noise.

- The increased cross section of the

suspension member enables the

reduced idle booming noise.

- Gas type shock absorber is applied

as a standard.

- Increased caster angle comparing SM (Santa Fe)

to give better performance while direct forward

driving. (SM: 2.5˚ JM: 3.5˚)

* Rear: Dual link

- The bushing mounting was applied on the rear cross member.

2WD 4WD

Θ

Solid type Bush type

- Operating voltage range: DC 8 ~ 16V

- Operating temperature range: -40 ~+80

- Storage temperature range: -40 ~+85

- Current consumption: 20mA(typ) 500mA(max)

- Frequency (Data transmitting): 134.2 kHz

JM - Introduction


- More enhanced design than XD was applied to improve the driving and steering feeling.

- Reduced NVH.

- Gas type shock absorber is applied as a standard.

1.2 Specifications

JM - Introduction


1.3 Dimension

JM - Introduction


Items

Model (All Area)

Overall Length (mm) 4,325

Overall Width (mm) 1,795 (1,830: with Side garnish)

Overall Height (mm) 1,680 (1,730: with Roof rack)

Wheel Base (mm) 2,630

Tread FRT 1,540

(mm) RR 1,540

Interior Length (mm) 1,800

Interior Width (mm) 1,485

Interior Height (mm) 1,215

Ground Clearance 195

(mm) Measuring at Sub frame

JM - Introduction


1.4 Performance - A/T

- M/T

JM - Introduction


1.5 Offroad Specifications

Climing angle: 39-41%

(DSL, M/T, GVW, Starts from stationery

condition)

Approach

angle

Breakover

Angle Departure

angle

Front axle

Clearance

Rear axle

Clearance

Running

Clearance

Maximum load capacity of roof rack: 75kg

28.2 o 200mm 195mm 19 o

200mm 31.9 o

JM - Introduction


jm introduction 20040205

Documents

servicetraining booklet

regulation rear center

general jm car

class x5 jm tray

knowledge of service

wheel base jm difference

dynamic feeling of jm

r16 tire