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SSANGYONG ACTYON 2006.03, Manual

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SSANGYONG ACTYON 2006.03 Manual Download Page 1032

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ACTYON 2006.03

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Summary of Contents for ACTYON 2006.03

Page 1: ...S 3 VEHICLE IDENTIFICATION 4 MAINTENANCE INTERVAL 5 RECOMMENDED FLUIDS AND LUBRICANTS 6 JACK UP POINTS DOTTED CIRCLES 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 8 ELECTRIC COMPONENTS AND LAYOUT 9 STANDARD BOLTS SPECIFICATIONS GENERAL 3 4 6 7 9 10 11 12 14 ...

Page 2: ...0 2 ACTYON 2006 03 0000 00 GENERAL ...

Page 3: ...0 3 GENERAL ACTYON 2006 03 0000 00 4110 01 GENERAL 1 DIMENSIONS ...

Page 4: ...0 4 ACTYON 2006 03 0000 00 GENERAL 2 SPECIFICATIONS ...

Page 5: ...0 5 GENERAL ACTYON 2006 03 0000 00 ...

Page 6: ...s Number Certification Label Engine Number The chassis number is stamped on the frame behind the front right tire The certification label is located on the driver s door sill The engine number is stamped on the lower area of cylinder block in the intake manifold side ...

Page 7: ...vere condition Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Shorten the service interval ...

Page 8: ...f fluid at any time occasionally then change every 60 000 km 6 Change automatic transmission fluid and every 60 000 km if the vehicle is mainly driven under severe conditions Towing a trailer or off road driving Inspect the leak of fluid at any time occasionlly 7 After completion of off road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for loosene...

Page 9: ...0 5 RECOMMENDED FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants Do not mix any different types or brands of oils or fluids This may cause damages Keep the specified levels when adding or replacing the fluids ...

Page 10: ...0 10 ACTYON 2006 03 0000 00 GENERAL 6 JACK UP POINTS ...

Page 11: ...0 11 GENERAL ACTYON 2006 03 0000 00 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 1 Functions of Terminal It is installed under the instrument panel and consists of 16 pins ...

Page 12: ...0 12 ACTYON 2006 03 0000 00 GENERAL 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 13: ...0 13 GENERAL ACTYON 2006 03 0000 00 2 Components Locator ...

Page 14: ...0 14 ACTYON 2006 03 0000 00 GENERAL 9 STANDARD BOLTS SPECIFICATIONS ...

Page 15: ...ng bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of abo...

Page 16: ......

Page 17: ...S 3 VEHICLE IDENTIFICATION 4 MAINTENANCE INTERVAL 5 RECOMMENDED FLUIDS AND LUBRICANTS 6 JACK UP POINTS DOTTED CIRCLES 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 8 ELECTRIC COMPONENTS AND LAYOUT 9 STANDARD BOLTS SPECIFICATIONS GENERAL 3 4 6 7 9 10 11 12 14 ...

Page 18: ...0 2 ACTYON 2006 03 0000 00 GENERAL ...

Page 19: ...0 3 GENERAL ACTYON 2006 03 0000 00 4110 01 GENERAL 1 DIMENSIONS ...

Page 20: ...0 4 ACTYON 2006 03 0000 00 GENERAL 2 SPECIFICATIONS ...

Page 21: ...0 5 GENERAL ACTYON 2006 03 0000 00 ...

Page 22: ...s Number Certification Label Engine Number The chassis number is stamped on the frame behind the front right tire The certification label is located on the driver s door sill The engine number is stamped on the lower area of cylinder block in the intake manifold side ...

Page 23: ...vere condition Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Shorten the service interval ...

Page 24: ...f fluid at any time occasionally then change every 60 000 km 6 Change automatic transmission fluid and every 60 000 km if the vehicle is mainly driven under severe conditions Towing a trailer or off road driving Inspect the leak of fluid at any time occasionlly 7 After completion of off road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for loosene...

Page 25: ...0 5 RECOMMENDED FLUIDS AND LUBRICANTS Use only Ssangyong recommended fluids and lubricants Do not mix any different types or brands of oils or fluids This may cause damages Keep the specified levels when adding or replacing the fluids ...

Page 26: ...0 10 ACTYON 2006 03 0000 00 GENERAL 6 JACK UP POINTS ...

Page 27: ...0 11 GENERAL ACTYON 2006 03 0000 00 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 1 Functions of Terminal It is installed under the instrument panel and consists of 16 pins ...

Page 28: ...0 12 ACTYON 2006 03 0000 00 GENERAL 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 29: ...0 13 GENERAL ACTYON 2006 03 0000 00 2 Components Locator ...

Page 30: ...0 14 ACTYON 2006 03 0000 00 GENERAL 9 STANDARD BOLTS SPECIFICATIONS ...

Page 31: ...ng bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of abo...

Page 32: ......

Page 33: ...YSTEM LAYOUT 6 LUBRICATION SYSTEM LAYOUT 7 COOLING SYSTEM LAYOUT 8 FUEL SYSTEM LAYOUT 9 FUEL SUPPLY SYSTEM 10 CLEANNESS 11 MAINTENANCE AND REPAIR 12 GUIDELINES FOR SERVICE WORK SAFETY 13 DURING SERVICE WORK FOR INSPECTION 14 DURING SERVICE WORK FOR ELECTRIC DEVICES 15 OWNER INSPECTIONS AND SERVICES 16 STANDARD BOLTS SPECIFICATIONS 3 5 10 12 14 16 18 20 22 23 28 30 34 36 37 41 ...

Page 34: ......

Page 35: ...01 3 ENGINE GENERAL ACTYON 2006 03 0000 00 0000 00 ENGINE GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 36: ...01 4 ACTYON 2006 03 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 37: ... FFH L VGT turbo charger C Engine oil dipstick M Engine D Oil separator PCV valve N Engine oil filler cap E Vacuum pump O PWM electric fan fan shroud F EGR valve P Power steering oil reservoir G Vacuum modulator Q Fuel filter priming pump H Brake fluid reservoir R Battery I ABS ESP modulator S Fuse box J Air cleaner assembly T Washer fluid reservoir ...

Page 38: ...01 6 ACTYON 2006 03 0000 00 ENGINE GENERAL 2 Engine And Sensors Camshaft Position Sensor Injector Glow Plug Common Rail Fuel Pressure Sensor Common Rail Booster Pressure Sensor ...

Page 39: ...01 7 ENGINE GENERAL ACTYON 2006 03 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 40: ...000 00 ENGINE GENERAL 3 Engine Accessories Related to ECU IP Interior Fuse Box Passenger Side Engine ECU Mounting Location Engine ECU main relay Hazard warning lamp VGT EGR vacuum modulators HFM HP pumpIMV 1 2 3 4 Installed ...

Page 41: ...Filter Sensor Service Interval Fuel Filter EU Only Replace every 30 000 km Draining water from fuel filter whenever replacing the engine oil General Replace every 25 000 km Draining water from fuel filter whenever replacing the engine oil Integrated with 2 PPSs Priming Pump Fuel Filter ...

Page 42: ...TYON 2006 03 0000 00 ENGINE GENERAL 3 ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Glow Plug Preheat Warning Lamp Cluster Alternator Starter motor Engine compartment fuse box PTC FFH 12V 115A 12V 2 2kw Battery ...

Page 43: ...NCTION 1 Glow plug terminal 1 4 2 No G5 for 4 cylinders Without D20DT 3 IG1 power supply terminal 4 Glow plug control signal ECU113 5 Ground terminal 6 Battery main wire 7 Preheat completion transmit terminal No use for vehicle without remote engine start 8 K line ECU 34 ...

Page 44: ...TAKE SYSTEM Supplying Compressed Air with Turbocharger s Operation Intake Manifold Intake outlet hose Front air duct Air cleaner Terbocharger intercooler Turbo charger Inter cooler Air cleaner To corresponding cylinders From intercooler Coolant port ...

Page 45: ...N 2006 03 0000 00 Recirculation of Exhaust Gas when EGR Valve Operates Turbocharger Intercooler EGR valve Exhaust gas Intake com pressed air HFM Sensor Plug in sensor Air cleaner Turbo charger Temperature Sensor Pretension graph ...

Page 46: ...1 14 ACTYON 2006 03 0000 00 ENGINE GENERAL 5 EXHAUST SYSTEM DOC Diesel Catalytic Converter Exhaust Manifold To turbo charger To EGR pipe From cylinders EEGR Pipe Passage for recirculation of exhaust gas ...

Page 47: ...on will happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the...

Page 48: ...01 16 ACTYON 2006 03 0000 00 ENGINE GENERAL 6 LUBRICATION SYSTEM Cylinder Head Cover Oil Pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil dipstick gauge ...

Page 49: ...happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake ...

Page 50: ...M Coolant Port Water Pump Pipe Radiator Assembly Cooling Fan and Fan Clutch Coolant outlet port Thermostat inside Cylinder block Reservoir Coolant inlet hose Radiator Coolant outlet hose PWM electric fan Radiator Coolant reservoir Coolant inlet hose Return hose ...

Page 51: ...01 19 ENGINE GENERAL ACTYON 2006 03 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 52: ...YSTEM Injector Fuel Filter Priming Pump Fuel filter Connector Priming pump HP Pump Fuel return port Venturi Low pres sure fuel supply port Fuel return port Fuel tempera ture sensor IMV connector IMV valve High pres sure fuel supply port 1 2 3 4 5 HP Pump ...

Page 53: ...01 21 ENGINE GENERAL ACTYON 2006 03 0000 00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor 1 2 3 4 5 ...

Page 54: ...on sensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decr...

Page 55: ... open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operating elements The core elements of fuel system has very...

Page 56: ...ce on the wiring harnesses and connectors in engine compartment Perform the diagnosis proceee with SCAN 100 refer to DI10 DIAGNOSIS section in this manual Locate the fault If the cause is from fuel system from priming pump to injector including return line follow the step 1 through step 3 above If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing ...

Page 57: ...nes The pipes should be tightened tospecified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to...

Page 58: ... by SCAN 100 after replacing the high pre ssure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it be comes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are curr ent faults and erase the history faults ...

Page 59: ...in heater see fuel system System Supplement And Remedy Against Water In Fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due ...

Page 60: ...aintenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the proper fluid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity en...

Page 61: ... Service Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregular or premature wear exists check the wheel alignment and check for damaged wheels While the tires and wheels are removed inspect the ...

Page 62: ...ed by personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works Ho...

Page 63: ...f contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of pola...

Page 64: ...m foreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembl...

Page 65: ...etween HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance ...

Page 66: ...hicle and then support with chassis stand before service work Before service work be sure to dis connect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work...

Page 67: ...rease on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line b...

Page 68: ...ce Be careful not to throw or drop each sensor or relay Securely connect each connector until hear a click sound 1 2 3 4 5 6 7 1 Lifting Positions 4 post lift As illustrated position the vehicle on the 4 post lift securely and block the front and rear of each tire not to move during working During lifting be sure to check whether vehicle is empty Board on lift connection device installed in front ...

Page 69: ...s These are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignmen...

Page 70: ...The cold oil will not drain back to the pan fast enough to give a true oil level reading Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Engine Coolant Level and Condition Check the washer fluid level in the reservoir Add fluid if necessary Windshield Washer Fluid Level 3 At Least Twice A Month Tire And Wheel Ins...

Page 71: ...xle Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Inspect the complete system inclu...

Page 72: ... the glove box and the console doors and any folding seat hardware Body Lubrication Service Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the c...

Page 73: ...01 41 ENGINE GENERAL ACTYON 2006 03 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 74: ...during bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of...

Page 75: ...YSTEM LAYOUT 6 LUBRICATION SYSTEM LAYOUT 7 COOLING SYSTEM LAYOUT 8 FUEL SYSTEM LAYOUT 9 FUEL SUPPLY SYSTEM 10 CLEANNESS 11 MAINTENANCE AND REPAIR 12 GUIDELINES FOR SERVICE WORK SAFETY 13 DURING SERVICE WORK FOR INSPECTION 14 DURING SERVICE WORK FOR ELECTRIC DEVICES 15 OWNER INSPECTIONS AND SERVICES 16 STANDARD BOLTS SPECIFICATIONS 3 5 10 12 14 16 18 20 22 23 28 30 34 36 37 41 ...

Page 76: ......

Page 77: ...01 3 ENGINE GENERAL ACTYON 2006 03 0000 00 0000 00 ENGINE GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 78: ...01 4 ACTYON 2006 03 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 79: ... FFH L VGT turbo charger C Engine oil dipstick M Engine D Oil separator PCV valve N Engine oil filler cap E Vacuum pump O PWM electric fan fan shroud F EGR valve P Power steering oil reservoir G Vacuum modulator Q Fuel filter priming pump H Brake fluid reservoir R Battery I ABS ESP modulator S Fuse box J Air cleaner assembly T Washer fluid reservoir ...

Page 80: ...01 6 ACTYON 2006 03 0000 00 ENGINE GENERAL 2 Engine And Sensors Camshaft Position Sensor Injector Glow Plug Common Rail Fuel Pressure Sensor Common Rail Booster Pressure Sensor ...

Page 81: ...01 7 ENGINE GENERAL ACTYON 2006 03 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 82: ...000 00 ENGINE GENERAL 3 Engine Accessories Related to ECU IP Interior Fuse Box Passenger Side Engine ECU Mounting Location Engine ECU main relay Hazard warning lamp VGT EGR vacuum modulators HFM HP pumpIMV 1 2 3 4 Installed ...

Page 83: ...Filter Sensor Service Interval Fuel Filter EU Only Replace every 30 000 km Draining water from fuel filter whenever replacing the engine oil General Replace every 25 000 km Draining water from fuel filter whenever replacing the engine oil Integrated with 2 PPSs Priming Pump Fuel Filter ...

Page 84: ...TYON 2006 03 0000 00 ENGINE GENERAL 3 ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM Glow Plug Preheat Warning Lamp Cluster Alternator Starter motor Engine compartment fuse box PTC FFH 12V 115A 12V 2 2kw Battery ...

Page 85: ...NCTION 1 Glow plug terminal 1 4 2 No G5 for 4 cylinders Without D20DT 3 IG1 power supply terminal 4 Glow plug control signal ECU113 5 Ground terminal 6 Battery main wire 7 Preheat completion transmit terminal No use for vehicle without remote engine start 8 K line ECU 34 ...

Page 86: ...TAKE SYSTEM Supplying Compressed Air with Turbocharger s Operation Intake Manifold Intake outlet hose Front air duct Air cleaner Terbocharger intercooler Turbo charger Inter cooler Air cleaner To corresponding cylinders From intercooler Coolant port ...

Page 87: ...N 2006 03 0000 00 Recirculation of Exhaust Gas when EGR Valve Operates Turbocharger Intercooler EGR valve Exhaust gas Intake com pressed air HFM Sensor Plug in sensor Air cleaner Turbo charger Temperature Sensor Pretension graph ...

Page 88: ...1 14 ACTYON 2006 03 0000 00 ENGINE GENERAL 5 EXHAUST SYSTEM DOC Diesel Catalytic Converter Exhaust Manifold To turbo charger To EGR pipe From cylinders EEGR Pipe Passage for recirculation of exhaust gas ...

Page 89: ...on will happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the...

Page 90: ...01 16 ACTYON 2006 03 0000 00 ENGINE GENERAL 6 LUBRICATION SYSTEM Cylinder Head Cover Oil Pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil dipstick gauge ...

Page 91: ...happen when blow by gas passes through baffle plates in cylinder head cover Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake ...

Page 92: ...M Coolant Port Water Pump Pipe Radiator Assembly Cooling Fan and Fan Clutch Coolant outlet port Thermostat inside Cylinder block Reservoir Coolant inlet hose Radiator Coolant outlet hose PWM electric fan Radiator Coolant reservoir Coolant inlet hose Return hose ...

Page 93: ...01 19 ENGINE GENERAL ACTYON 2006 03 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 94: ...YSTEM Injector Fuel Filter Priming Pump Fuel filter Connector Priming pump HP Pump Fuel return port Venturi Low pres sure fuel supply port Fuel return port Fuel tempera ture sensor IMV connector IMV valve High pres sure fuel supply port 1 2 3 4 5 HP Pump ...

Page 95: ...01 21 ENGINE GENERAL ACTYON 2006 03 0000 00 Cylinder Head Fuel return hose Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor 1 2 3 4 5 ...

Page 96: ...on sensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decr...

Page 97: ... open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operating elements The core elements of fuel system has very...

Page 98: ...ce on the wiring harnesses and connectors in engine compartment Perform the diagnosis proceee with SCAN 100 refer to DI10 DIAGNOSIS section in this manual Locate the fault If the cause is from fuel system from priming pump to injector including return line follow the step 1 through step 3 above If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing ...

Page 99: ...nes The pipes should be tightened tospecified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to...

Page 100: ... by SCAN 100 after replacing the high pre ssure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it be comes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are curr ent faults and erase the history faults ...

Page 101: ...in heater see fuel system System Supplement And Remedy Against Water In Fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due ...

Page 102: ...aintenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the proper fluid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity en...

Page 103: ... Service Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregular or premature wear exists check the wheel alignment and check for damaged wheels While the tires and wheels are removed inspect the ...

Page 104: ...ed by personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works Ho...

Page 105: ...f contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of pola...

Page 106: ...m foreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembl...

Page 107: ...etween HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance ...

Page 108: ...hicle and then support with chassis stand before service work Before service work be sure to dis connect battery negative terminal to prevent damages by bad wire and short 1 2 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work...

Page 109: ...rease on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line b...

Page 110: ...ce Be careful not to throw or drop each sensor or relay Securely connect each connector until hear a click sound 1 2 3 4 5 6 7 1 Lifting Positions 4 post lift As illustrated position the vehicle on the 4 post lift securely and block the front and rear of each tire not to move during working During lifting be sure to check whether vehicle is empty Board on lift connection device installed in front ...

Page 111: ...s These are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignmen...

Page 112: ...The cold oil will not drain back to the pan fast enough to give a true oil level reading Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Engine Coolant Level and Condition Check the washer fluid level in the reservoir Add fluid if necessary Windshield Washer Fluid Level 3 At Least Twice A Month Tire And Wheel Ins...

Page 113: ...xle Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Inspect the complete system inclu...

Page 114: ... the glove box and the console doors and any folding seat hardware Body Lubrication Service Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the c...

Page 115: ...01 41 ENGINE GENERAL ACTYON 2006 03 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 116: ...during bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of...

Page 117: ...ly controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque Coolant reservoir FFH Engine oil dipstick Oil separator PCV valve Vacuum pump Air cleaner assembly HFM sensor VGT Turbo charger Engine Engine oil filler cap ...

Page 118: ... ASSEMBLY ACTYON 2006 03 1212 01 EGR valve Vacuum modulator Brake fluid reservoir ABS ESP modulator Fuel filter priming pump Power steering oil reservoir PWM electric fan fan shroud Washer fluid reservoir Battery ...

Page 119: ...h PCV 4 VGT Turbo charger 5 EGR pipe 6 Water pump pulley 7 Alternator 8 Crankshaft pulley 9 Oil pan 10 Auto tensioner 11 Air conditioner compressor 12 Auto tensioner pulley 13 Power steering pump pulley 14 Power steering pump 15 EGR valve 16 Idle pulley 17 Viscos clutch pulley 1 Engine Structure Front View ...

Page 120: ...ector cover 10 1 0 Nm 180 20 3 Oil pipe 4 Fuel pressure sensor 5 Water outlet port 6 EGR valve 7 Oil filler 8 Booster pressure sensor 9 Common rail 10 Vacuum pump 11 Glow plug 12 Cylinder head cover 13 VGT Turbo charger Top View 40 4 0 Nm 25 2 5 Nm 10 1 0 Nm 15 3 Nm ...

Page 121: ... pump 5 HP pump assembly 6 Air conditioner compressor 7 Engine mounting bracket 8 Vacuum modulator for VGT turbocharger actuator 9 Flywheel 10 Crank position sensor 11 Vacuum modulator for EGR valve 12 Oil filter oil cooler 13 Vacuum pump 14 Booster pressure sensor 15 Intake manifold Gap 0 7 1 5 mm Right Side View 20 2 6 Nm ...

Page 122: ... 03 1212 01 1 Cylinder head jack valve screw 2 VGT Turbo charger assembly 3 Cylinder block assembly 4 Engine mounting bracket 5 Oil pan 6 Alternator 7 Water pump 8 EGR pipe 9 Oil dipstick gauge 10 Oil separator with PCV Left Side View ...

Page 123: ...02 8 ACTYON 2006 03 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 124: ...02 9 ENGINE ASSEMBLY ACTYON 2006 03 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 125: ...02 10 ACTYON 2006 03 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 126: ...02 11 ENGINE ASSEMBLY ACTYON 2006 03 1212 01 ...

Page 127: ...02 12 ACTYON 2006 03 1212 01 ENGINE ASSEMBLY ...

Page 128: ...ly controlled D20DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque Coolant reservoir FFH Engine oil dipstick Oil separator PCV valve Vacuum pump Air cleaner assembly HFM sensor VGT Turbo charger Engine Engine oil filler cap ...

Page 129: ... ASSEMBLY ACTYON 2006 03 1212 01 EGR valve Vacuum modulator Brake fluid reservoir ABS ESP modulator Fuel filter priming pump Power steering oil reservoir PWM electric fan fan shroud Washer fluid reservoir Battery ...

Page 130: ...h PCV 4 VGT Turbo charger 5 EGR pipe 6 Water pump pulley 7 Alternator 8 Crankshaft pulley 9 Oil pan 10 Auto tensioner 11 Air conditioner compressor 12 Auto tensioner pulley 13 Power steering pump pulley 14 Power steering pump 15 EGR valve 16 Idle pulley 17 Viscos clutch pulley 1 Engine Structure Front View ...

Page 131: ...ector cover 10 1 0 Nm 180 20 3 Oil pipe 4 Fuel pressure sensor 5 Water outlet port 6 EGR valve 7 Oil filler 8 Booster pressure sensor 9 Common rail 10 Vacuum pump 11 Glow plug 12 Cylinder head cover 13 VGT Turbo charger Top View 40 4 0 Nm 25 2 5 Nm 10 1 0 Nm 15 3 Nm ...

Page 132: ... pump 5 HP pump assembly 6 Air conditioner compressor 7 Engine mounting bracket 8 Vacuum modulator for VGT turbocharger actuator 9 Flywheel 10 Crank position sensor 11 Vacuum modulator for EGR valve 12 Oil filter oil cooler 13 Vacuum pump 14 Booster pressure sensor 15 Intake manifold Gap 0 7 1 5 mm Right Side View 20 2 6 Nm ...

Page 133: ... 03 1212 01 1 Cylinder head jack valve screw 2 VGT Turbo charger assembly 3 Cylinder block assembly 4 Engine mounting bracket 5 Oil pan 6 Alternator 7 Water pump 8 EGR pipe 9 Oil dipstick gauge 10 Oil separator with PCV Left Side View ...

Page 134: ...02 8 ACTYON 2006 03 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 135: ...02 9 ENGINE ASSEMBLY ACTYON 2006 03 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 136: ...02 10 ACTYON 2006 03 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 137: ...02 11 ENGINE ASSEMBLY ACTYON 2006 03 1212 01 ...

Page 138: ...02 12 ACTYON 2006 03 1212 01 ENGINE ASSEMBLY ...

Page 139: ...m and stops engine operation Refer to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining pr...

Page 140: ...ter drain plug water separating operation every 10 000km 3 Priming pump When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The water drain from fuel filter should be performed whenever changing the engine oil ...

Page 141: ...uel gets out from the port then turn the drain plug to B direction to tighten it 3 Be careful not to be injured by surrounding equipment during the working procedures Press the priming pump until it becomes rigid 4 Start the engine and check the conditions 5 If the priming pump is not properly operated air may get into the fuel line It may cause starting problem or fuel system problem Make sure to...

Page 142: ...mand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from coolant temperatu...

Page 143: ...mpletely different from injection pump type fuel supply system on the conventional Diesel engine The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure high pressure section that transfers fuel in high pressure and ECU control section High pressure pipe Common rail Fuel pressure sensor Priming pump Fuel pump High pressure pump t...

Page 144: ...03 8 ACTYON 2006 03 1881 01 ENGINE FUEL SYSTEM 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE High pressure supply line Transfer pressure supply line Return line ...

Page 145: ...event excessive pressure building Also to supply fuel smoothly it has structure to prevent fuel from leaking in shocks slopes and corners and If fuel runs out during driving or air gets into fuel line after fuel filter replacement it may cause poor engine starting or damage to each component Therefore the hand priming pump is installed to bleed air from transfer line When the vehicle is under the ...

Page 146: ...materials in the fuel fuel system including pump components delivery valve and injector nozzles may be damaged Fuel filter purifies fuel before it reaches to high pressure pump to help proper operations in high pressure pump And more it separates water from fuel to prevent water from getting into FIE system high pressure line 3 Fuel filter ...

Page 147: ...creases system pressure of fuel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High pressure pump It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a specific value...

Page 148: ...njector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel returned by low pressure and fuel used for high pressure pump lubrication also return to fuel tank through return line 6 Fuel filter replacement Fuel filter ...

Page 149: ...03 13 ENGINE FUEL SYSTEM ACTYON 2006 03 1881 01 6 CIRCUIT DIAGRAM ...

Page 150: ...03 14 ACTYON 2006 03 1881 01 ENGINE FUEL SYSTEM ...

Page 151: ...03 15 ENGINE FUEL SYSTEM ACTYON 2006 03 1881 01 ...

Page 152: ......

Page 153: ...m and stops engine operation Refer to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining pr...

Page 154: ...ter drain plug water separating operation every 10 000km 3 Priming pump When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The water drain from fuel filter should be performed whenever changing the engine oil ...

Page 155: ...uel gets out from the port then turn the drain plug to B direction to tighten it 3 Be careful not to be injured by surrounding equipment during the working procedures Press the priming pump until it becomes rigid 4 Start the engine and check the conditions 5 If the priming pump is not properly operated air may get into the fuel line It may cause starting problem or fuel system problem Make sure to...

Page 156: ...mand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from coolant temperatu...

Page 157: ...mpletely different from injection pump type fuel supply system on the conventional Diesel engine The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure high pressure section that transfers fuel in high pressure and ECU control section High pressure pipe Common rail Fuel pressure sensor Priming pump Fuel pump High pressure pump t...

Page 158: ...03 8 ACTYON 2006 03 1881 01 ENGINE FUEL SYSTEM 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE High pressure supply line Transfer pressure supply line Return line ...

Page 159: ...event excessive pressure building Also to supply fuel smoothly it has structure to prevent fuel from leaking in shocks slopes and corners and If fuel runs out during driving or air gets into fuel line after fuel filter replacement it may cause poor engine starting or damage to each component Therefore the hand priming pump is installed to bleed air from transfer line When the vehicle is under the ...

Page 160: ...materials in the fuel fuel system including pump components delivery valve and injector nozzles may be damaged Fuel filter purifies fuel before it reaches to high pressure pump to help proper operations in high pressure pump And more it separates water from fuel to prevent water from getting into FIE system high pressure line 3 Fuel filter ...

Page 161: ...creases system pressure of fuel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High pressure pump It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a specific value...

Page 162: ...njector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel returned by low pressure and fuel used for high pressure pump lubrication also return to fuel tank through return line 6 Fuel filter replacement Fuel filter ...

Page 163: ...03 13 ENGINE FUEL SYSTEM ACTYON 2006 03 1881 01 6 CIRCUIT DIAGRAM ...

Page 164: ...03 14 ACTYON 2006 03 1881 01 ENGINE FUEL SYSTEM ...

Page 165: ...03 15 ENGINE FUEL SYSTEM ACTYON 2006 03 1881 01 ...

Page 166: ......

Page 167: ...lement Type Service Interval Initial cleaning 5 000 km Clean or change every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2321 01 ENGINE INTAKE SYSTEM ...

Page 168: ...the air temperature Major Functions It controls the EGR feedback It controls the pressure control valve for the turbocharger booster 1 Plug in sensor 2 Cylinder housing 3 Protection grid 4 Hybrid cover 5 Measuring duct cover 6 Housing 7 Hybrid 8 Sensor 9 Mounting plate 10 O ring 11 Temperature sensor Turbocharger actuator Intake air cleaner Com pressed air intercooler Exhaust gas Exhaust pipe dies...

Page 169: ...wered or the knocking may happen as the intake air is heated and the density of air is lowered The intercooler is the device which cools the supercharged air Intake manifold Intake air Exhaust gas Exhaust gas Intake manifold Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum pump EGR valve IP interior fuse RH No 63 7 5A Engine ECU No 96 Intake Manifold Intake air ...

Page 170: ...04 6 ACTYON 2006 03 0000 00 ENGINE INTAKE SYSTEM 2 Layout ...

Page 171: ...ntial and helical port which increases the swirl ratio in mid low operating range improves acceleration fuel consumption and decreases particle materials However there are some differences in the form of the EGR valve and 4 cylinder engine The inlet port and coolant outlet port is integrated together Therefore be careful not to let the residual coolant in the manifold enter the inlet port when rem...

Page 172: ...GR valve 4 Intake air intercooler Intake Manifold Incoming of intake air and exhaust gas Operation of EGR valve Incoming of intake air No operation of EGR valve Coolant emission port Coolant emission port The SUS Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect Intake air Intake air Exhaust gas ...

Page 173: ...ession process in the turbocharger compressor and the density is lowered The intercooler is the device which cools 50 60 C the air entering the engine from high temperature 100 110 C to maintain the turbocharging efficiency Thus more air is entered the cylinder than the engine only with the turbocharger to give more power Intercooler For removal and installation procedures refer to the Cooling sys...

Page 174: ...04 10 ACTYON 2006 03 0000 00 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 175: ...lement Type Service Interval Initial cleaning 5 000 km Clean or change every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2321 01 ENGINE INTAKE SYSTEM ...

Page 176: ...the air temperature Major Functions It controls the EGR feedback It controls the pressure control valve for the turbocharger booster 1 Plug in sensor 2 Cylinder housing 3 Protection grid 4 Hybrid cover 5 Measuring duct cover 6 Housing 7 Hybrid 8 Sensor 9 Mounting plate 10 O ring 11 Temperature sensor Turbocharger actuator Intake air cleaner Com pressed air intercooler Exhaust gas Exhaust pipe dies...

Page 177: ...wered or the knocking may happen as the intake air is heated and the density of air is lowered The intercooler is the device which cools the supercharged air Intake manifold Intake air Exhaust gas Exhaust gas Intake manifold Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum pump EGR valve IP interior fuse RH No 63 7 5A Engine ECU No 96 Intake Manifold Intake air ...

Page 178: ...04 6 ACTYON 2006 03 0000 00 ENGINE INTAKE SYSTEM 2 Layout ...

Page 179: ...ntial and helical port which increases the swirl ratio in mid low operating range improves acceleration fuel consumption and decreases particle materials However there are some differences in the form of the EGR valve and 4 cylinder engine The inlet port and coolant outlet port is integrated together Therefore be careful not to let the residual coolant in the manifold enter the inlet port when rem...

Page 180: ...GR valve 4 Intake air intercooler Intake Manifold Incoming of intake air and exhaust gas Operation of EGR valve Incoming of intake air No operation of EGR valve Coolant emission port Coolant emission port The SUS Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect Intake air Intake air Exhaust gas ...

Page 181: ...ession process in the turbocharger compressor and the density is lowered The intercooler is the device which cools 50 60 C the air entering the engine from high temperature 100 110 C to maintain the turbocharging efficiency Thus more air is entered the cylinder than the engine only with the turbocharger to give more power Intercooler For removal and installation procedures refer to the Cooling sys...

Page 182: ...04 10 ACTYON 2006 03 0000 00 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 183: ... complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to re...

Page 184: ...uce the amount of the fuel injection in no load rapid acceleration mode the IDI engine s HUBER EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative pressure to occur in the vacuum modulator to reduce the amount of fuel injection When DI engine basing input signal from the related sensors such as acceleration pedal sensor and engine RPM ...

Page 185: ...st Manifold EGR Valve and Installation Location 1 EXHAUST SYSTEM LAYOUT Intake manifold Intake manifold EGR pipe Intake manifold Intake air intercooler EGR pipe LH To turbo charger To EGR valve Exhaust manifold Diesel catalytic converter Muffler EGR pipe RH ...

Page 186: ...05 6 ACTYON 2006 03 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 187: ... complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time the controller has to re...

Page 188: ...uce the amount of the fuel injection in no load rapid acceleration mode the IDI engine s HUBER EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative pressure to occur in the vacuum modulator to reduce the amount of fuel injection When DI engine basing input signal from the related sensors such as acceleration pedal sensor and engine RPM ...

Page 189: ...st Manifold EGR Valve and Installation Location 1 EXHAUST SYSTEM LAYOUT Intake manifold Intake manifold EGR pipe Intake manifold Intake air intercooler EGR pipe LH To turbo charger To EGR valve Exhaust manifold Diesel catalytic converter Muffler EGR pipe RH ...

Page 190: ...05 6 ACTYON 2006 03 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 191: ...are less than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km When operating in dusty sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing Operating temperature Operating pressure 0 3 0 55 bar Permissible pressure 10 bar Severe Condition 2 OIL PRESSURE SWITCH 1533 01 LUBRICATION SYSTEM 40 140 C ...

Page 192: ...will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Cylinder head cover oil gas Inlet port Blow by gas air duct hose Oil oil g...

Page 193: ...06 5 LUBRICATION SYSTEM ACTYON 2006 03 1533 01 Cylinder Head Cover Oil pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil Filter Oil Cooler Oil cooler Oil filter ...

Page 194: ... LUBRICATION SYSTEM Cylinder Head Cylinder Block 2 Lubrication System Layout Main oil gallery Hole to cylinder head Main bearing hole Chain and injection pump Return hole Chain nozzle HP pump bearing φ 16 φ 9 φ 7 φ 7 φ 14 φ 1 φ 6 ...

Page 195: ...YON 2006 03 1533 01 2 LUBRICATION DIAGRAM Opening pressure of by pass valve in oil filter 3 0 4 bar To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head ...

Page 196: ...are less than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km When operating in dusty sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing Operating temperature Operating pressure 0 3 0 55 bar Permissible pressure 10 bar Severe Condition 2 OIL PRESSURE SWITCH 1533 01 LUBRICATION SYSTEM 40 140 C ...

Page 197: ...will be separated due to cyclone effect after entering the oil separator inlet port Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens closes due to pressure differences between the intake side and crankcase Cylinder head cover oil gas Inlet port Blow by gas air duct hose Oil oil g...

Page 198: ...06 5 LUBRICATION SYSTEM ACTYON 2006 03 1533 01 Cylinder Head Cover Oil pressure Warning Lamp Cluster Oil Pan and Baffle Plate Integrated Type Oil Strainer Oil Filter Oil Cooler Oil cooler Oil filter ...

Page 199: ... LUBRICATION SYSTEM Cylinder Head Cylinder Block 2 Lubrication System Layout Main oil gallery Hole to cylinder head Main bearing hole Chain and injection pump Return hole Chain nozzle HP pump bearing φ 16 φ 9 φ 7 φ 7 φ 14 φ 1 φ 6 ...

Page 200: ...YON 2006 03 1533 01 2 LUBRICATION DIAGRAM Opening pressure of by pass valve in oil filter 3 0 4 bar To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head ...

Page 201: ...07 3 COOLING SYSTEM ACTYON 2006 03 2112 01 9210 05 ENGINE COOLING SYSTEM 1 ENGINE COOLING SPECIFICATIONS ...

Page 202: ...07 4 ACTYON 2006 03 2112 01 COOLING SYSTEM Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING ...

Page 203: ...01 PTC Engine Coolant Flows FFH Engine Coolant Flows 2 COOLING SYSTEM FLOW Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 204: ...ver in D27DT engine coolant inflows from cylinder block through oil cooler refer to coolant flows layout in previous page In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected to water pump with an additional pulley Cylinder head Intake manifold Coolant outlet port Improved shape and gasket material to prevent coolant from leaking It prevents...

Page 205: ...07 3 COOLING SYSTEM ACTYON 2006 03 2112 01 9210 05 ENGINE COOLING SYSTEM 1 ENGINE COOLING SPECIFICATIONS ...

Page 206: ...07 4 ACTYON 2006 03 2112 01 COOLING SYSTEM Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING ...

Page 207: ...01 PTC Engine Coolant Flows FFH Engine Coolant Flows 2 COOLING SYSTEM FLOW Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 208: ...ver in D27DT engine coolant inflows from cylinder block through oil cooler refer to coolant flows layout in previous page In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected to water pump with an additional pulley Cylinder head Intake manifold Coolant outlet port Improved shape and gasket material to prevent coolant from leaking It prevents...

Page 209: ...08 3 ENGINE ELECTRIC DEVICES ACTYON 2006 03 1451 01 1461 01 ENGINE ELECTRICAL SYSTEM 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 210: ...ELECTRIC DEVICES Fuel Pressure Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor 1 COMPONENTS OF ELECTRIC IN ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 211: ...INE ELECTRIC DEVICES ACTYON 2006 03 1451 01 Alternator Glow Plug Air Conditioner Compressor Starter 2 COMPONENTS OF ELECTRIC DEVICES IN ENGIN Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 212: ...08 6 ACTYON 2006 03 1451 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 213: ...08 7 ENGINE ELECTRIC DEVICES ACTYON 2006 03 1451 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 214: ...08 3 ENGINE ELECTRIC DEVICES ACTYON 2006 03 1451 01 1461 01 ENGINE ELECTRICAL SYSTEM 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 215: ...ELECTRIC DEVICES Fuel Pressure Sensor Camshaft Position Sensor Coolant Temperature Sensor Fuel Temperature Sensor 1 COMPONENTS OF ELECTRIC IN ENGINE Booster Pressure Sensor Oil Pressure Switch Crankshaft Position Sensor Knock Sensor 1 EA ...

Page 216: ...INE ELECTRIC DEVICES ACTYON 2006 03 1451 01 Alternator Glow Plug Air Conditioner Compressor Starter 2 COMPONENTS OF ELECTRIC DEVICES IN ENGIN Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 217: ...08 6 ACTYON 2006 03 1451 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 218: ...08 7 ENGINE ELECTRIC DEVICES ACTYON 2006 03 1451 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 219: ...PONENTS Water Pump and Pipe Coolant Port Engine Oil Filter and Cooler Cylinder block Reservior coolant inlet hose Radiator Thermostat inside Coolant outlet port Oil cooler Oil filter Oil cooler Oil Filter cap Oil pressure switch Radiator Coolant outlet hose Return hose Coolant reservoir Coolant inlet hose ...

Page 220: ...09 4 ACTYON 2006 03 1491 01 ENGINE CONTROL SYSTEM 2 TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 221: ...09 5 ENGINE CONTROL SYSTEM ACTYON 2006 03 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 222: ...ankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preheater auxilia...

Page 223: ... range of ECU is normally 40 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circuit divides current applying time...

Page 224: ...ncomplete combustion So there occurs smoke and damages engine durability Fuel pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined a...

Page 225: ...ming advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities which are liabl...

Page 226: ... is made according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a functio...

Page 227: ...ot flow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order...

Page 228: ...ssure As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand Until the stating phase has finished the system uses the supercharged fuel Once the engine changes to normal operation the system uses the total fuel A switch makes it possible to change over from the supercharge fuel to the total fuel ...

Page 229: ...ines the maximum fuel which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and ch...

Page 230: ...smoke emissions to be reduced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of ...

Page 231: ...re the altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The ...

Page 232: ...annot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection The accelerometer does not allow any evaluation of the quantity injected However the pulse value will be measured when the injector starts injection ...

Page 233: ...ust be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled an...

Page 234: ...ersion the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors...

Page 235: ...ost optimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number ...

Page 236: ...ed mininum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 237: ...PONENTS Water Pump and Pipe Coolant Port Engine Oil Filter and Cooler Cylinder block Reservior coolant inlet hose Radiator Thermostat inside Coolant outlet port Oil cooler Oil filter Oil cooler Oil Filter cap Oil pressure switch Radiator Coolant outlet hose Return hose Coolant reservoir Coolant inlet hose ...

Page 238: ...09 4 ACTYON 2006 03 1491 01 ENGINE CONTROL SYSTEM 2 TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 239: ...09 5 ENGINE CONTROL SYSTEM ACTYON 2006 03 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 240: ...ankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preheater auxilia...

Page 241: ... range of ECU is normally 40 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circuit divides current applying time...

Page 242: ...ncomplete combustion So there occurs smoke and damages engine durability Fuel pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined a...

Page 243: ...ming advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities which are liabl...

Page 244: ... is made according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a functio...

Page 245: ...ot flow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order...

Page 246: ...ssure As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand Until the stating phase has finished the system uses the supercharged fuel Once the engine changes to normal operation the system uses the total fuel A switch makes it possible to change over from the supercharge fuel to the total fuel ...

Page 247: ...ines the maximum fuel which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and ch...

Page 248: ...smoke emissions to be reduced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of ...

Page 249: ...re the altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The ...

Page 250: ...annot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection The accelerometer does not allow any evaluation of the quantity injected However the pulse value will be measured when the injector starts injection ...

Page 251: ...ust be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled an...

Page 252: ...ersion the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors...

Page 253: ...ost optimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number ...

Page 254: ...ed mininum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 255: ...eering wheel and when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without usi...

Page 256: ...orways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 257: ...10 5 CRUISE CONTROL SYSTEM ACTYON 2006 03 8510 23 2 CIRCUIT DIAGRAM 1 CONFIGURATION ...

Page 258: ...ed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never ...

Page 259: ...e and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ...

Page 260: ...is over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to ...

Page 261: ...r like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle sp...

Page 262: ...as an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may ...

Page 263: ...eering wheel and when this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without usi...

Page 264: ...orways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 265: ...10 5 CRUISE CONTROL SYSTEM ACTYON 2006 03 8510 23 2 CIRCUIT DIAGRAM 1 CONFIGURATION ...

Page 266: ...ed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow And then release the accelerator pedal slowly Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never ...

Page 267: ...e and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ...

Page 268: ...is over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to ...

Page 269: ...r like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle sp...

Page 270: ...as an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may ...

Page 271: ...AND RELAY BOX There are three fuse and relay boxes in this vehicle one at each side of instrument panel and one in engine compartment The designation and capacity of relays and fuses is shown on the fuse and relay box cover 1 FUSE AND RELAY BOX IN ENGINE COMPARTMENT Fuses and Relays Connector Arrangement ...

Page 272: ...0 4 ACTYON 2006 03 8410 02 FUSES AND REALYS 2 INTERIOR FUSES AND RELAYS Fuse and Relay Box LH Fuse and Relay Box RH ...

Page 273: ...0 5 FUSES AND REALYS ACTYON 2006 03 8410 02 2 DESIGNATION AND CAPACITY OF FUSES AND RELAY 1 Fuses and Relays in Engine ...

Page 274: ...0 6 ACTYON 2006 03 8410 02 FUSES AND REALYS 2 Designation and Capacity 1 Driver Side ...

Page 275: ...R valve vacuum modulator HP pump IMV and HFM No 63 fuse 7 5A This is marked as the engine ECU fuse However this receives the power from the main relay and supplies it to the turbocharger EGR vacuum modulator and HFM No 64 fuse 7 5A This supplies the power to the HP pump IMV If this is blown out IMV opens fully so too many fuel is delivered ...

Page 276: ...0 8 ACTYON 2006 03 8410 02 FUSES AND REALYS 3 POWER DISTRIBUTION For details refer to the electric circuit diagram ...

Page 277: ...0 9 FUSES AND REALYS ACTYON 2006 03 8410 02 For details refer to the electric circuit diagram ...

Page 278: ...0 10 ACTYON 2006 03 8410 02 FUSES AND REALYS 4 POWER DISTRIBUTION OF INTERIOR FUSE 1 IP Interior Fuse Driver Side For details refer to the electric circuit diagram ...

Page 279: ...0 11 FUSES AND REALYS ACTYON 2006 03 8410 02 2 IP Interior Fuse Passenger Side For details refer to the electric circuit diagram ...

Page 280: ...AND RELAY BOX There are three fuse and relay boxes in this vehicle one at each side of instrument panel and one in engine compartment The designation and capacity of relays and fuses is shown on the fuse and relay box cover 1 FUSE AND RELAY BOX IN ENGINE COMPARTMENT Fuses and Relays Connector Arrangement ...

Page 281: ...0 4 ACTYON 2006 03 8410 02 FUSES AND REALYS 2 INTERIOR FUSES AND RELAYS Fuse and Relay Box LH Fuse and Relay Box RH ...

Page 282: ...0 5 FUSES AND REALYS ACTYON 2006 03 8410 02 2 DESIGNATION AND CAPACITY OF FUSES AND RELAY 1 Fuses and Relays in Engine ...

Page 283: ...0 6 ACTYON 2006 03 8410 02 FUSES AND REALYS 2 Designation and Capacity 1 Driver Side ...

Page 284: ...R valve vacuum modulator HP pump IMV and HFM No 63 fuse 7 5A This is marked as the engine ECU fuse However this receives the power from the main relay and supplies it to the turbocharger EGR vacuum modulator and HFM No 64 fuse 7 5A This supplies the power to the HP pump IMV If this is blown out IMV opens fully so too many fuel is delivered ...

Page 285: ...0 8 ACTYON 2006 03 8410 02 FUSES AND REALYS 3 POWER DISTRIBUTION For details refer to the electric circuit diagram ...

Page 286: ...0 9 FUSES AND REALYS ACTYON 2006 03 8410 02 For details refer to the electric circuit diagram ...

Page 287: ...0 10 ACTYON 2006 03 8410 02 FUSES AND REALYS 4 POWER DISTRIBUTION OF INTERIOR FUSE 1 IP Interior Fuse Driver Side For details refer to the electric circuit diagram ...

Page 288: ...0 11 FUSES AND REALYS ACTYON 2006 03 8410 02 2 IP Interior Fuse Passenger Side For details refer to the electric circuit diagram ...

Page 289: ...GES Auto Washer Coupled Wiper When pressing the auto washer switch the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times and then the washer fluid is sprayed and the wiper sweeps off 3 times again Auto Light Sensor and Rain Sensor The auto light sensor integrated rain sensor communicates with STICS Tailgate Open Relay Control Tailgate unlock switch Installed on the tailgat...

Page 290: ...l Performance Characteristics of Radio Wave Transmitting frequency 447 800 0 0125 MHz Channel width below 12 5 KHz Frequency bandwidth below 8 5 KHz Modulation method FSK Frequency Shift Keying Receiving distance Approx 10 15 m In case there are not obstacles around the system 1 2 3 4 5 ...

Page 291: ...02 5 STICS ACTYON 2006 03 8710 01 Rated Load ...

Page 292: ...02 6 ACTYON 2006 03 8710 01 STICS Input Signals ...

Page 293: ...in each function does not include the vehicle speed calculating time 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time fro...

Page 294: ... been a dded to the RK STICS REKES STICS Super Time Integrated Control System The tailgate open switch is installed on the tailgate It activates the tailgate relay when operating the tailgate open switch Door Lock Relay PAS Buzzer RK STICS Chime Buzzer Tailgate Open Switch ...

Page 295: ... Operates automatically according to the vehicle speed or the amount of rain Continuous wipe slow operation Front Automatic Wiping Speed Control Switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in the AUTO position Fast Fast interval Slow Slow interval Continuous wipe fast operation MIST AUTO OFF LO HI Front wip...

Page 296: ...operate only while holding the switch When releasing the switch it returns to the rear wiper operate position Front Auto Washer and Wiper Switch When pressing the auto washer switch with the wiper switch OFF the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times after then the washer fluid is sprayed and the wiper sweeps off 3 times again Rear Washer and Wiper The rear wash...

Page 297: ...ned on for 0 1 to 0 59 seconds T2 with the ignition switch ON If the wiper parking terminal gets off the wiper relay is turned off 1 The wiper relay is turned on at 0 3 seconds T1 after from the time when the washer switch is turned on for more than 0 6 seconds T2 with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch 2 ...

Page 298: ...he washer switch is turned on for more than 0 6 seconds during the wiper operation by INT switch the operation in step 2 is performed When it is turned on for a certain period of time 0 1 to 0 59 seconds the operation in step 1 is performed 3 ...

Page 299: ...rear washer motor relay output gets ON from the time when the rear washer switch is turned on It gets OFF when the rear washer switch is turned off This control is not available while the front washer switch or the auto washer and wiper AFW Advanced Fast Washer is in operation 1 2 3 Rear Washer Motor Control ...

Page 300: ...h ON and the INT switch OFF the washer motor output gets ON for 1 second If the system recognizes the output signal the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second Then the wiper relay output gets OFF after 3 cycles 1 4 Auto Washer and Wiper Switch AFW ...

Page 301: ...on the auto washer operation stops and the auto INT operation is activated 2 3 4 5 Priorities in Washer Operations he rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden...

Page 302: ...02 16 ACTYON 2006 03 8710 01 STICS 5 Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor it has following operation system System layout ...

Page 303: ...he wiper switch is turned to the ON position again from other positions the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Rain Detected signal 1 2 Rain sensing unit AUTO light integrated type A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounti...

Page 304: ...er switch input with the ignition switch ON and the auto INT switch ON in the rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during the continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 ...

Page 305: ...nsitivity is increased while the ignition key is in the ON position the wiper switch is in the ON position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle 1 ...

Page 306: ...le the ignition key is in ON position and the wiper switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 When the parking terminal is fixed to IGN the wiper system outputs the wiper operating signal for 2 seconds then continuously outputs the wiper parking signal The wiper motor runs only when the rain sensor requires the wiper operation 2 ...

Page 307: ...ving the malfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 1 The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 2 ...

Page 308: ...als in the ICM box It rains but the system does not work in the AUTO position Symptom 2 Check whether the multifunction wiper switch is in the AUTO position Check the power to the sensor Check the conditions of the pin 3 Ground and the pin 4 IGN Check the wiper relay for defective Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest st...

Page 309: ... wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 310: ...cted headlamp If it rains heavy which requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 2 3 Emitter lense Auto light se...

Page 311: ...switch positioned to ON Intermittent interval at 0 km h 3 0 5 19 2 seconds Vehicle speed calculation Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 PULSE SEC 60 km h X 60 sec 637 X 4 PULSE 1 41 km h The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume input voltage Each level has the hysteresis VOLUME calculation Pause ti...

Page 312: ...h OFF Resume the intermittent time when turning ON IGN 2 switch OFF INT switch ON Resume the intermittent time when turning ON Controls when the wiper motor parking is defective The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiperrelay is ON INT switch ON or Washer switch ON The output stops immediately after turning off the switch The output ...

Page 313: ...ON WARNING The chime buzzer sounds continuously when opening the driver s door while the ignition key is in ignition switch When removing the ignition key or closing the driver s door during chime buzzer operation the buzzer stops This function is not available when the ignition switch is in ON position 1 2 3 PAS buzzer Chime buzzer ...

Page 314: ...e system outputs UNLOCK signal for 5 seconds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch If the UNLOCK conditions are met the system outputs UNLOCK signal unconditionally However if the ignition key is removed after the door lock switch is changed from UNLOCK to LOCK the system does ...

Page 315: ...s is open When the door is closed during the UNLOCK output the UNLOCK output stops immediately When the ignition key is inserted during the output the output continues for approx 5 seconds If the ignition switch is in the ON position or the ignition switch is removed the above steps are performed If the key is in the key cylinder the ignition key reminder function is activated This function does n...

Page 316: ...d on and the ignition key is removed The chime buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal for 5 seconds when the driver s and passenger s door lock switch is locked while the tail lamp is turned on and the driver s door is open This function is not available when the ignition key is in the ON position 1 2 3 4 ...

Page 317: ...rning light goes off when closing the door under step 1 The warning light blinks when the vehicle speed is over 10 km h while the warning light is turned on The warning light blinks when a door is open while the vehicle speed is over 10 km h The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle speed goes below 10 km h under step 3 1 2 3 4 5 6 ...

Page 318: ...en turning the ignition switch to the OFF position The chime buzzer stops and the seat belt warning light stays on for the specified period of time when fastening the seat belt during the warning operation The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the seat belt during fastening operation while the ignition key is ON position 1 2 3 4 Seat ...

Page 319: ... on while the vehicle speed is below 10 km h 3 The warning light goes off when turning off the parking brake switch under step 2 4 The warning light blinks and the chime buzzer in the ICM box sounds for 2 85 seconds and stops for 1 5 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on 5 The warning light goes off and the chime buzzer s...

Page 320: ... key during the dimming operation The front room lamp and the center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and the center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output The lamp stays on when unlocked by the remot...

Page 321: ...n a door is opened and goes off when the door is closed The front and center room lamps come on when pressing the room lamp main switch 3 Center Room Lamp If the switch is at the door coupled position the center room lamp comes on when a door is opened The lamp always comes on while the switch is at the other position Driver s seat Tailgate Center Room Lamp Lamp ON Center Room Lamp Door coupled op...

Page 322: ... 1 The output stops when the ignition key is turned to the ON position The output stops when receiving the lock signal from the remote control key under armed mode 1 2 3 4 20 Ignition Key Hole Illumination Key cylinder with key hole illumination For diesel and gasoline engine equipped vehicle Without immobilizer With key hole illumination For diesel engine equipped vehicle With immobilizer With ke...

Page 323: ...t when opening and closing the driver s door while the ignition key is removed and the tail lamp is turned on 1 2 3 4 21 Tail Lamp Auto Cut Battery Saver The front defogger output is ON when turning ON the front defogger switch while the ignition switch is ON with engine running The output stops when turning on the defogger switch again during its operation The output is ON only for 6 minutes when...

Page 324: ...ON with engine running The output is OFF when turning ON the rear defogger switch again during output The output is ON only for 6 minutes when turning ON the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the IGN 2 switch is OFF 23 Rear Defogger Timer ...

Page 325: ...stem outputs UNLOCK signal for 0 5 seconds when positioning the driver s or passenger s door lock switch to the unlock position LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK signal by other functions All door lock signals are UNLOCK for 0 5 seconds just for once when receiving the LOCK signal within 0 5 seconds after closing the driver s or passenger s door w...

Page 326: ...conds while LOCK switches in all doors are in UNLOCK position and the vehicle speed is 0 Km h STICS operates the tailgate relay for 0 5 seconds to unlock the tailgate If any LOCK switch is switched to LOCK position or vehicle speed exceeds 3 Km h while operating the tailgate open relay the output of the tailgate relay gets OFF 1 2 ...

Page 327: ...ystem outputs LOCK UNLOCK signal for 0 5 seconds when operating the central door lock switch However if the door lock switch front doors is at LOCK position the system outputs UNLOCK signal and vice versa The LOCK or UNLOCK inputs from the central door lock switch in anti theft mode are ignored 1 2 ...

Page 328: ...7 Door LOCK UNLOCK by Remote Control Key The door lock relay output is ON for 0 5 seconds when receiving the remote control lock signal The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal 1 2 ...

Page 329: ...and accelerates again to over 50 km h Nonetheless the central door lock function works properly When the system receives UNLOCK signal from a door switch it outputs LOCK signals 5 times If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals 5 times for the door The door lock system outputs UNLOCK automatically if the LOCK output condit...

Page 330: ...tput continues on for remaining period The function is erased when turning OFF the IGN switch 1 2 3 4 The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK o...

Page 331: ...d mode during its extended operation period of 30 seconds 1 2 3 31 Definition of Terms DOOR OPEN and DOOR CLOSE DOOR OPEN Any of all door switches including hood and tailgate is in OPEN position DOOR CLOSE All door switches including hood and tailgate are in CLOSE position 1 The door lock unlock operation does not affect the engine hood DOOR LOCK Indicates that all door lock switches including tai...

Page 332: ...m the remote control key while any of doors is not closed only the LOCK output can be done and then activates the armed ready mode without theft deterrent horn and hazard warning flasher At this moment if the ignition key is in the ignition switch the door unlock switch is turned ON or the door lock switch is unlocked it cancels the armed mode and activates the normal mode When the door is not ope...

Page 333: ...arning flasher output is ON for 27 seconds with the interval of 1 second Warning cancellation requirements a Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC during warning operation b Cancels warning after 27 seconds remaining period while the ignition key is turned to ON position c If the ignition switch is turned to ON position when the warning is activated in a...

Page 334: ...When any of switches on remote control key is pressed the integrated CPU in remote control key sends the coded control message to the CPU in receiver to control the vehicle Switch Functions on Remote Control Key Door button 1 Door lock press briefly The door is locked and it goes into the armed mode when pressing this button for 0 1 0 5 seconds a 2 Door unlock press and hold The door is unlocked a...

Page 335: ...r LOCK switch on remote control key less than 0 5 seconds The system outputs LOCK signal immediately after receiving the door lock message from the remote control key The system activates the theft deterrent mode when all doors are locked while they are fully closed the hazard warning lamps blink twice 1 2 ...

Page 336: ...or 0 5 seconds when receiving the door unlock message from the remote control key The hazard warning lamps blink once only when all the doors unlocked 1 2 3 36 Auto Door Lock in 30 Seconds after Pressing Door Unlock Button If no door is opened for 30 seconds after inputting remote door unlock the doors are automatically locked and the armed mode of anti theft system is activated again 1 ...

Page 337: ...02 51 STICS ACTYON 2006 03 8710 01 3 CIRCUIT DIAGRAM The circuit diagram below shows the input and output of STICS 1 STICS Input Singnals and Others ...

Page 338: ...02 52 ACTYON 2006 03 8710 01 STICS 2 STICS Output Signals and Others ...

Page 339: ...uto washer switch is turned on when the ignition key is ON and the INT switch is OFF the washer motor output gets ON for approx one second since the auto washer switch is turned on When the washer motor output is detected the wiper relay output gets ON for 4 cycles Then the washer motor output gets ON for 1 second the wiper relay output gets ON for 3 cycles and gets OFF ...

Page 340: ...tion key reminder is a convenience function to prevent the driver from leaving the vehicle with the tail lamps ON or without removing the key As shown in the figure STICS monitors the signal of key reminder and controls the vehicle according to the door switch and tail lamp conditions For details refer to following information ...

Page 341: ... Wiring Circuit of STICS Related to Seat Belt Parking Brake Warning STICS monitors the seat belt fastening status and the parking brake engagement status and warns the driver with the warning light on the instrument panel or chime buzzer ...

Page 342: ...e door s opening and closing status and UNLOCK signal of the remote controller The operating time control and dimming functions of room lamp have been introduced for user convenience The ignition key reminder warning signal in the circuit is related to the dimming function Refer to the detailed information in this manual for the control logic ...

Page 343: ...02 57 STICS ACTYON 2006 03 8710 01 7 WiringCircuitofSTICS RelatedtoTailLampAutoCut BatterySaver ...

Page 344: ...ressing this switch The defogger system defrosts or demists the window glass with the heated wire integrated in glass When operating the defogger switch STICS controls the operating time only in IGN2 position Tailgate window and outside rearview mirror heated glass switch The tailgate window and outside rearview mirror heated glass is turned on for 12 minutes when pressing this switch ...

Page 345: ...02 59 STICS ACTYON 2006 03 8710 01 9 Circuit Diagram of STICS Related to Remote Controller and Door Lock Unlock ...

Page 346: ......

Page 347: ...GES Auto Washer Coupled Wiper When pressing the auto washer switch the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times and then the washer fluid is sprayed and the wiper sweeps off 3 times again Auto Light Sensor and Rain Sensor The auto light sensor integrated rain sensor communicates with STICS Tailgate Open Relay Control Tailgate unlock switch Installed on the tailgat...

Page 348: ...l Performance Characteristics of Radio Wave Transmitting frequency 447 800 0 0125 MHz Channel width below 12 5 KHz Frequency bandwidth below 8 5 KHz Modulation method FSK Frequency Shift Keying Receiving distance Approx 10 15 m In case there are not obstacles around the system 1 2 3 4 5 ...

Page 349: ...02 5 STICS ACTYON 2006 03 8710 01 Rated Load ...

Page 350: ...02 6 ACTYON 2006 03 8710 01 STICS Input Signals ...

Page 351: ...in each function does not include the vehicle speed calculating time 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time fro...

Page 352: ... been a dded to the RK STICS REKES STICS Super Time Integrated Control System The tailgate open switch is installed on the tailgate It activates the tailgate relay when operating the tailgate open switch Door Lock Relay PAS Buzzer RK STICS Chime Buzzer Tailgate Open Switch ...

Page 353: ... Operates automatically according to the vehicle speed or the amount of rain Continuous wipe slow operation Front Automatic Wiping Speed Control Switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in the AUTO position Fast Fast interval Slow Slow interval Continuous wipe fast operation MIST AUTO OFF LO HI Front wip...

Page 354: ...operate only while holding the switch When releasing the switch it returns to the rear wiper operate position Front Auto Washer and Wiper Switch When pressing the auto washer switch with the wiper switch OFF the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times after then the washer fluid is sprayed and the wiper sweeps off 3 times again Rear Washer and Wiper The rear wash...

Page 355: ...ned on for 0 1 to 0 59 seconds T2 with the ignition switch ON If the wiper parking terminal gets off the wiper relay is turned off 1 The wiper relay is turned on at 0 3 seconds T1 after from the time when the washer switch is turned on for more than 0 6 seconds T2 with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch 2 ...

Page 356: ...he washer switch is turned on for more than 0 6 seconds during the wiper operation by INT switch the operation in step 2 is performed When it is turned on for a certain period of time 0 1 to 0 59 seconds the operation in step 1 is performed 3 ...

Page 357: ...rear washer motor relay output gets ON from the time when the rear washer switch is turned on It gets OFF when the rear washer switch is turned off This control is not available while the front washer switch or the auto washer and wiper AFW Advanced Fast Washer is in operation 1 2 3 Rear Washer Motor Control ...

Page 358: ...h ON and the INT switch OFF the washer motor output gets ON for 1 second If the system recognizes the output signal the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second Then the wiper relay output gets OFF after 3 cycles 1 4 Auto Washer and Wiper Switch AFW ...

Page 359: ...on the auto washer operation stops and the auto INT operation is activated 2 3 4 5 Priorities in Washer Operations he rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden...

Page 360: ...02 16 ACTYON 2006 03 8710 01 STICS 5 Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor it has following operation system System layout ...

Page 361: ...he wiper switch is turned to the ON position again from other positions the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Rain Detected signal 1 2 Rain sensing unit AUTO light integrated type A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounti...

Page 362: ...er switch input with the ignition switch ON and the auto INT switch ON in the rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during the continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 ...

Page 363: ...nsitivity is increased while the ignition key is in the ON position the wiper switch is in the ON position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal If the volume sensitivity is changed more than 2 stages within 2 seconds the wiper motor runs only one cycle 1 ...

Page 364: ...le the ignition key is in ON position and the wiper switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 When the parking terminal is fixed to IGN the wiper system outputs the wiper operating signal for 2 seconds then continuously outputs the wiper parking signal The wiper motor runs only when the rain sensor requires the wiper operation 2 ...

Page 365: ...ving the malfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 1 The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the wiper switch is in ON position 2 ...

Page 366: ...als in the ICM box It rains but the system does not work in the AUTO position Symptom 2 Check whether the multifunction wiper switch is in the AUTO position Check the power to the sensor Check the conditions of the pin 3 Ground and the pin 4 IGN Check the wiper relay for defective Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest st...

Page 367: ... wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 368: ...cted headlamp If it rains heavy which requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 2 3 Emitter lense Auto light se...

Page 369: ...switch positioned to ON Intermittent interval at 0 km h 3 0 5 19 2 seconds Vehicle speed calculation Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 PULSE SEC 60 km h X 60 sec 637 X 4 PULSE 1 41 km h The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume input voltage Each level has the hysteresis VOLUME calculation Pause ti...

Page 370: ...h OFF Resume the intermittent time when turning ON IGN 2 switch OFF INT switch ON Resume the intermittent time when turning ON Controls when the wiper motor parking is defective The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiperrelay is ON INT switch ON or Washer switch ON The output stops immediately after turning off the switch The output ...

Page 371: ...ON WARNING The chime buzzer sounds continuously when opening the driver s door while the ignition key is in ignition switch When removing the ignition key or closing the driver s door during chime buzzer operation the buzzer stops This function is not available when the ignition switch is in ON position 1 2 3 PAS buzzer Chime buzzer ...

Page 372: ...e system outputs UNLOCK signal for 5 seconds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch If the UNLOCK conditions are met the system outputs UNLOCK signal unconditionally However if the ignition key is removed after the door lock switch is changed from UNLOCK to LOCK the system does ...

Page 373: ...s is open When the door is closed during the UNLOCK output the UNLOCK output stops immediately When the ignition key is inserted during the output the output continues for approx 5 seconds If the ignition switch is in the ON position or the ignition switch is removed the above steps are performed If the key is in the key cylinder the ignition key reminder function is activated This function does n...

Page 374: ...d on and the ignition key is removed The chime buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal for 5 seconds when the driver s and passenger s door lock switch is locked while the tail lamp is turned on and the driver s door is open This function is not available when the ignition key is in the ON position 1 2 3 4 ...

Page 375: ...rning light goes off when closing the door under step 1 The warning light blinks when the vehicle speed is over 10 km h while the warning light is turned on The warning light blinks when a door is open while the vehicle speed is over 10 km h The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle speed goes below 10 km h under step 3 1 2 3 4 5 6 ...

Page 376: ...en turning the ignition switch to the OFF position The chime buzzer stops and the seat belt warning light stays on for the specified period of time when fastening the seat belt during the warning operation The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the seat belt during fastening operation while the ignition key is ON position 1 2 3 4 Seat ...

Page 377: ... on while the vehicle speed is below 10 km h 3 The warning light goes off when turning off the parking brake switch under step 2 4 The warning light blinks and the chime buzzer in the ICM box sounds for 2 85 seconds and stops for 1 5 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on 5 The warning light goes off and the chime buzzer s...

Page 378: ... key during the dimming operation The front room lamp and the center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and the center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output The lamp stays on when unlocked by the remot...

Page 379: ...n a door is opened and goes off when the door is closed The front and center room lamps come on when pressing the room lamp main switch 3 Center Room Lamp If the switch is at the door coupled position the center room lamp comes on when a door is opened The lamp always comes on while the switch is at the other position Driver s seat Tailgate Center Room Lamp Lamp ON Center Room Lamp Door coupled op...

Page 380: ... 1 The output stops when the ignition key is turned to the ON position The output stops when receiving the lock signal from the remote control key under armed mode 1 2 3 4 20 Ignition Key Hole Illumination Key cylinder with key hole illumination For diesel and gasoline engine equipped vehicle Without immobilizer With key hole illumination For diesel engine equipped vehicle With immobilizer With ke...

Page 381: ...t when opening and closing the driver s door while the ignition key is removed and the tail lamp is turned on 1 2 3 4 21 Tail Lamp Auto Cut Battery Saver The front defogger output is ON when turning ON the front defogger switch while the ignition switch is ON with engine running The output stops when turning on the defogger switch again during its operation The output is ON only for 6 minutes when...

Page 382: ...ON with engine running The output is OFF when turning ON the rear defogger switch again during output The output is ON only for 6 minutes when turning ON the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the IGN 2 switch is OFF 23 Rear Defogger Timer ...

Page 383: ...stem outputs UNLOCK signal for 0 5 seconds when positioning the driver s or passenger s door lock switch to the unlock position LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK signal by other functions All door lock signals are UNLOCK for 0 5 seconds just for once when receiving the LOCK signal within 0 5 seconds after closing the driver s or passenger s door w...

Page 384: ...conds while LOCK switches in all doors are in UNLOCK position and the vehicle speed is 0 Km h STICS operates the tailgate relay for 0 5 seconds to unlock the tailgate If any LOCK switch is switched to LOCK position or vehicle speed exceeds 3 Km h while operating the tailgate open relay the output of the tailgate relay gets OFF 1 2 ...

Page 385: ...ystem outputs LOCK UNLOCK signal for 0 5 seconds when operating the central door lock switch However if the door lock switch front doors is at LOCK position the system outputs UNLOCK signal and vice versa The LOCK or UNLOCK inputs from the central door lock switch in anti theft mode are ignored 1 2 ...

Page 386: ...7 Door LOCK UNLOCK by Remote Control Key The door lock relay output is ON for 0 5 seconds when receiving the remote control lock signal The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal 1 2 ...

Page 387: ...and accelerates again to over 50 km h Nonetheless the central door lock function works properly When the system receives UNLOCK signal from a door switch it outputs LOCK signals 5 times If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals 5 times for the door The door lock system outputs UNLOCK automatically if the LOCK output condit...

Page 388: ...tput continues on for remaining period The function is erased when turning OFF the IGN switch 1 2 3 4 The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK o...

Page 389: ...d mode during its extended operation period of 30 seconds 1 2 3 31 Definition of Terms DOOR OPEN and DOOR CLOSE DOOR OPEN Any of all door switches including hood and tailgate is in OPEN position DOOR CLOSE All door switches including hood and tailgate are in CLOSE position 1 The door lock unlock operation does not affect the engine hood DOOR LOCK Indicates that all door lock switches including tai...

Page 390: ...m the remote control key while any of doors is not closed only the LOCK output can be done and then activates the armed ready mode without theft deterrent horn and hazard warning flasher At this moment if the ignition key is in the ignition switch the door unlock switch is turned ON or the door lock switch is unlocked it cancels the armed mode and activates the normal mode When the door is not ope...

Page 391: ...arning flasher output is ON for 27 seconds with the interval of 1 second Warning cancellation requirements a Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC during warning operation b Cancels warning after 27 seconds remaining period while the ignition key is turned to ON position c If the ignition switch is turned to ON position when the warning is activated in a...

Page 392: ...When any of switches on remote control key is pressed the integrated CPU in remote control key sends the coded control message to the CPU in receiver to control the vehicle Switch Functions on Remote Control Key Door button 1 Door lock press briefly The door is locked and it goes into the armed mode when pressing this button for 0 1 0 5 seconds a 2 Door unlock press and hold The door is unlocked a...

Page 393: ...r LOCK switch on remote control key less than 0 5 seconds The system outputs LOCK signal immediately after receiving the door lock message from the remote control key The system activates the theft deterrent mode when all doors are locked while they are fully closed the hazard warning lamps blink twice 1 2 ...

Page 394: ...or 0 5 seconds when receiving the door unlock message from the remote control key The hazard warning lamps blink once only when all the doors unlocked 1 2 3 36 Auto Door Lock in 30 Seconds after Pressing Door Unlock Button If no door is opened for 30 seconds after inputting remote door unlock the doors are automatically locked and the armed mode of anti theft system is activated again 1 ...

Page 395: ...02 51 STICS ACTYON 2006 03 8710 01 3 CIRCUIT DIAGRAM The circuit diagram below shows the input and output of STICS 1 STICS Input Singnals and Others ...

Page 396: ...02 52 ACTYON 2006 03 8710 01 STICS 2 STICS Output Signals and Others ...

Page 397: ...uto washer switch is turned on when the ignition key is ON and the INT switch is OFF the washer motor output gets ON for approx one second since the auto washer switch is turned on When the washer motor output is detected the wiper relay output gets ON for 4 cycles Then the washer motor output gets ON for 1 second the wiper relay output gets ON for 3 cycles and gets OFF ...

Page 398: ...tion key reminder is a convenience function to prevent the driver from leaving the vehicle with the tail lamps ON or without removing the key As shown in the figure STICS monitors the signal of key reminder and controls the vehicle according to the door switch and tail lamp conditions For details refer to following information ...

Page 399: ... Wiring Circuit of STICS Related to Seat Belt Parking Brake Warning STICS monitors the seat belt fastening status and the parking brake engagement status and warns the driver with the warning light on the instrument panel or chime buzzer ...

Page 400: ...e door s opening and closing status and UNLOCK signal of the remote controller The operating time control and dimming functions of room lamp have been introduced for user convenience The ignition key reminder warning signal in the circuit is related to the dimming function Refer to the detailed information in this manual for the control logic ...

Page 401: ...02 57 STICS ACTYON 2006 03 8710 01 7 WiringCircuitofSTICS RelatedtoTailLampAutoCut BatterySaver ...

Page 402: ...ressing this switch The defogger system defrosts or demists the window glass with the heated wire integrated in glass When operating the defogger switch STICS controls the operating time only in IGN2 position Tailgate window and outside rearview mirror heated glass switch The tailgate window and outside rearview mirror heated glass is turned on for 12 minutes when pressing this switch ...

Page 403: ...02 59 STICS ACTYON 2006 03 8710 01 9 Circuit Diagram of STICS Related to Remote Controller and Door Lock Unlock ...

Page 404: ......

Page 405: ...allowing only the authorized key to start the engine The transponder inside the key communicates with the immobilizer installed in the key box and the system permits the engine to start after confirming the encrypted coding from the engine ECU Refer to the information that follows for specific functions and their descriptions Immobilizer Transponder Battery ...

Page 406: ...icle the theft deterrent mode is activated 1 Door and tailgate unlock press and hold All doors and tailgate are unlocked and the theft deterrent mode is deactivated The front room lamp and the center room lamp come on for 30 seconds The lamps go off immediately when the LOCK signal is sent from the remote control key room lamp coupled unction 2 Door button Key plate 1 Engine start 2 Door lock unlo...

Page 407: ......

Page 408: ...bilizer unit transmits the encrypted code to the transponder Immobilizer Unit The transmitted code is changed to an encrypted signal in the unit The system compares the signal from transponder and the encrypted signal in immobilizer unit In the following cases a driver may be unable to start the vehicle with the immobilizer When two or more immobilizer keys come into contact with each other s When...

Page 409: ...ts the challenge message to the immobilizer unit to verify whether the key is valid Only when the two signals are identical it recognizes the key as the authorized one and transmits the positive message to the ECU Do not drop or shock to the transponder in the key as it may be damaged With a damaged transponder the engine cannot be started When you erase the code or register an extra key let the o...

Page 410: ...trol key for less than 0 5 seconds all doors are locked The system outputs the LOCK signal immediately after receiving the door lock message from the remote control key If the vehicle is locked while all doors including tailgate and engine hood are closed the theft deterrent mode is activated hazard warning lamps are blinking twice 1 2 ...

Page 411: ...k switch on the remote control key for more than 0 5 seconds all doors are unlocked When receiving the DOOR UNLOCK message from the remote control key the door unlock relay is turned on for 0 5 seconds The hazard warning lamps blink once only when the doors are successfully unlocked 1 2 3 ...

Page 412: ...03 10 ACTYON 2006 03 7010 06 IMMO 5 CIRCUIT DIAGRAM ...

Page 413: ...allowing only the authorized key to start the engine The transponder inside the key communicates with the immobilizer installed in the key box and the system permits the engine to start after confirming the encrypted coding from the engine ECU Refer to the information that follows for specific functions and their descriptions Immobilizer Transponder Battery ...

Page 414: ...icle the theft deterrent mode is activated 1 Door and tailgate unlock press and hold All doors and tailgate are unlocked and the theft deterrent mode is deactivated The front room lamp and the center room lamp come on for 30 seconds The lamps go off immediately when the LOCK signal is sent from the remote control key room lamp coupled unction 2 Door button Key plate 1 Engine start 2 Door lock unlo...

Page 415: ......

Page 416: ...bilizer unit transmits the encrypted code to the transponder Immobilizer Unit The transmitted code is changed to an encrypted signal in the unit The system compares the signal from transponder and the encrypted signal in immobilizer unit In the following cases a driver may be unable to start the vehicle with the immobilizer When two or more immobilizer keys come into contact with each other s When...

Page 417: ...ts the challenge message to the immobilizer unit to verify whether the key is valid Only when the two signals are identical it recognizes the key as the authorized one and transmits the positive message to the ECU Do not drop or shock to the transponder in the key as it may be damaged With a damaged transponder the engine cannot be started When you erase the code or register an extra key let the o...

Page 418: ...trol key for less than 0 5 seconds all doors are locked The system outputs the LOCK signal immediately after receiving the door lock message from the remote control key If the vehicle is locked while all doors including tailgate and engine hood are closed the theft deterrent mode is activated hazard warning lamps are blinking twice 1 2 ...

Page 419: ...k switch on the remote control key for more than 0 5 seconds all doors are unlocked When receiving the DOOR UNLOCK message from the remote control key the door unlock relay is turned on for 0 5 seconds The hazard warning lamps blink once only when the doors are successfully unlocked 1 2 3 ...

Page 420: ...03 10 ACTYON 2006 03 7010 06 IMMO 5 CIRCUIT DIAGRAM ...

Page 421: ...IPTIONS OF INDICATOR DISPLAY The instrument cluster sends and receives the signals to and from the relevant control units through CAN communication The HDC warning light and the engine hood open warning light are newly introduced 8010 01 CLUSTER ...

Page 422: ...igh 6 Immobilizer indicator 20 EBD warning light 7 4WD HIGH indicator 21 ABS warning light 8 4WD CHECK warning light 22 Engine oil pressure warning light 9 Water separator warning light 23 Glow indicator 10 Seat belt reminder 24 Low fuel level warning light 11 Speedometer 25 Engine hood open warning light 12 ODOmeter Trip odometer 26 Over temperature warning light 13 Coolant temperature gauge 27 P...

Page 423: ...05 4 ACTYON 2006 03 8010 01 CLUSTER 2 WARNING INDICATOR PANEL ...

Page 424: ...05 5 CLUSTER ACTYON 2006 03 8010 01 ...

Page 425: ...ipped with gasoline engine the indicator shows up to 7 000 rpm and 8 000 rpm The tolerance at 7 000 rpm is 100 Connect the tachometer for tune up test and start the engine Eliminate the hysteresis by tapping the tachometer Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive If the tachometer pointer vibrates stands at a certain range or sounds a...

Page 426: ...an abnormal noise there could be defectives in speedometer However these symptoms also could be occured when the tire has uneven wear different tire inflation pressures or different tire specifications The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range Perform the speedometer test regarding the tolerance as described However it is not similar s...

Page 427: ...ed to instrument panel TCU TCCU and engine ECU via CAN communication If the speedometer gauge vibrates stops at a certain range or makes an abnormal noise there could be defectives in speedometer However these symptoms also could be occured when the tire has uneven wear different tire inflation pressures or different tire specifications This table shows the tolerance and resistance value changes b...

Page 428: ...ature is as shown below Measurement of coolant temperature sensor resistance Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out of specified range Resistance value by coolant temperature When the resistance value by coolant temperature is within the specified range check thermostat water pump radiator related coolant circuit for normal ...

Page 429: ...0 01 CLUSTER 2 TRIP ODOmeter TRIP A TRIP B and ODOmeter Odometer Trip Odometer When pressing the TRIP RESET switch on the center panel the odometer trip odometer is converted and the meter resets to 0 0 km in Trip A and Trip B ...

Page 430: ...has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Basically the brake system apos s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON HDC system...

Page 431: ...s the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors Then the ESP warning lamp on the instrument panel comes on The detailed operation procedures are as follows 1 The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms 2 The switch returns to normal position when the OFF switch is released 3 The ES...

Page 432: ...itch returns to normal position when the OFF switch is released 3 The ESP system will be resumed after approx 150 ms When turning the ignition switch off while the ESP system is activated the ESP system will be resumed when ignition switch is turned on again When the vehicle is controlled by ESP system during driving the ESP OFF switch does not operate The ESP OFF switch operates when it is pushed...

Page 433: ...ines it as a ESP OFF switch malfunction When the ESP OFF switch is pushed the ESP system is resumed after 10 seconds However the ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms and then goes out when the ESP system is resumed When the ESP OFF switch returns to normal position the ESP unit resets the ESP OFF switch for approx 3 5 seconds ...

Page 434: ...Conditions The table shows ESP warning lamp operations when the ESP system is defective or ESP including TCS function is working When the driver presses the brake pedal during the ESP OFF mode the yaw control is performed to compensate the vehicle stability posture during ESP operation ...

Page 435: ...05 16 ACTYON 2006 03 8010 01 CLUSTER 4 CIRCUIT DIAGRAM ...

Page 436: ...05 17 CLUSTER ACTYON 2006 03 8010 01 ...

Page 437: ...IPTIONS OF INDICATOR DISPLAY The instrument cluster sends and receives the signals to and from the relevant control units through CAN communication The HDC warning light and the engine hood open warning light are newly introduced 8010 01 CLUSTER ...

Page 438: ...igh 6 Immobilizer indicator 20 EBD warning light 7 4WD HIGH indicator 21 ABS warning light 8 4WD CHECK warning light 22 Engine oil pressure warning light 9 Water separator warning light 23 Glow indicator 10 Seat belt reminder 24 Low fuel level warning light 11 Speedometer 25 Engine hood open warning light 12 ODOmeter Trip odometer 26 Over temperature warning light 13 Coolant temperature gauge 27 P...

Page 439: ...05 4 ACTYON 2006 03 8010 01 CLUSTER 2 WARNING INDICATOR PANEL ...

Page 440: ...05 5 CLUSTER ACTYON 2006 03 8010 01 ...

Page 441: ...ipped with gasoline engine the indicator shows up to 7 000 rpm and 8 000 rpm The tolerance at 7 000 rpm is 100 Connect the tachometer for tune up test and start the engine Eliminate the hysteresis by tapping the tachometer Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive If the tachometer pointer vibrates stands at a certain range or sounds a...

Page 442: ...an abnormal noise there could be defectives in speedometer However these symptoms also could be occured when the tire has uneven wear different tire inflation pressures or different tire specifications The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range Perform the speedometer test regarding the tolerance as described However it is not similar s...

Page 443: ...ed to instrument panel TCU TCCU and engine ECU via CAN communication If the speedometer gauge vibrates stops at a certain range or makes an abnormal noise there could be defectives in speedometer However these symptoms also could be occured when the tire has uneven wear different tire inflation pressures or different tire specifications This table shows the tolerance and resistance value changes b...

Page 444: ...ature is as shown below Measurement of coolant temperature sensor resistance Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out of specified range Resistance value by coolant temperature When the resistance value by coolant temperature is within the specified range check thermostat water pump radiator related coolant circuit for normal ...

Page 445: ...0 01 CLUSTER 2 TRIP ODOmeter TRIP A TRIP B and ODOmeter Odometer Trip Odometer When pressing the TRIP RESET switch on the center panel the odometer trip odometer is converted and the meter resets to 0 0 km in Trip A and Trip B ...

Page 446: ...has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Basically the brake system apos s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON HDC system...

Page 447: ...s the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors Then the ESP warning lamp on the instrument panel comes on The detailed operation procedures are as follows 1 The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms 2 The switch returns to normal position when the OFF switch is released 3 The ES...

Page 448: ...itch returns to normal position when the OFF switch is released 3 The ESP system will be resumed after approx 150 ms When turning the ignition switch off while the ESP system is activated the ESP system will be resumed when ignition switch is turned on again When the vehicle is controlled by ESP system during driving the ESP OFF switch does not operate The ESP OFF switch operates when it is pushed...

Page 449: ...ines it as a ESP OFF switch malfunction When the ESP OFF switch is pushed the ESP system is resumed after 10 seconds However the ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms and then goes out when the ESP system is resumed When the ESP OFF switch returns to normal position the ESP unit resets the ESP OFF switch for approx 3 5 seconds ...

Page 450: ...Conditions The table shows ESP warning lamp operations when the ESP system is defective or ESP including TCS function is working When the driver presses the brake pedal during the ESP OFF mode the yaw control is performed to compensate the vehicle stability posture during ESP operation ...

Page 451: ...05 16 ACTYON 2006 03 8010 01 CLUSTER 4 CIRCUIT DIAGRAM ...

Page 452: ...05 17 CLUSTER ACTYON 2006 03 8010 01 ...

Page 453: ...06 3 LAMP ACTYON 2006 03 8310 01 Front Fog Light Side Repeater Headlamp 8310 01 LAMP 1 LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS Headlamp Position lamp and Turn Signal Lamp Push Push ...

Page 454: ...06 4 ACTYON 2006 03 8310 01 LAMP High Mounted Stop Lamp License Plate Lamp Rear Fog Light Rear Combination Lamp Stop lamp Tail lamp Back up lamp Turn signal lamp ...

Page 455: ...1 2 However the front lamps are turned on when opening a door and turned off when closing it The front room lamps and center lamp are turned on when pressing the room lamp main switch 3 Center Room Lamp When this switch is pushed towards the rear of the vehicle the lamp comes on when opening a door and goes off in 30 seconds If the switch is pushed to the opposite direction the lamp stays on Towar...

Page 456: ...should stop immediately after turning on the ignition key during decaying operation The front room lamp and center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output Th...

Page 457: ...06 3 LAMP ACTYON 2006 03 8310 01 Front Fog Light Side Repeater Headlamp 8310 01 LAMP 1 LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS Headlamp Position lamp and Turn Signal Lamp Push Push ...

Page 458: ...06 4 ACTYON 2006 03 8310 01 LAMP High Mounted Stop Lamp License Plate Lamp Rear Fog Light Rear Combination Lamp Stop lamp Tail lamp Back up lamp Turn signal lamp ...

Page 459: ...1 2 However the front lamps are turned on when opening a door and turned off when closing it The front room lamps and center lamp are turned on when pressing the room lamp main switch 3 Center Room Lamp When this switch is pushed towards the rear of the vehicle the lamp comes on when opening a door and goes off in 30 seconds If the switch is pushed to the opposite direction the lamp stays on Towar...

Page 460: ...should stop immediately after turning on the ignition key during decaying operation The front room lamp and center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output Th...

Page 461: ...rs press it again Rear Fog Lamp Switch ESP OFF Switch If you press the ESP OFF switch the ESP function stops and the indicator lamp in instrument panel comes on Press this switch again to resume the ESP function At this time the indicator lamp goes out Driver s Power Window Switch Driver can controls all door windows Open Close Lock Unlock and doors Lock Unlock with this switch unit ...

Page 462: ... To choose a desired driving distance display mode press the switch Changing sequence ODO TRIP A TRIP B ODO Auto light position Front Wiper and Washer Coupled Operation Pull the lever briefly below 0 6 seconds One wiping cycle Pull and hold the lever for more than 0 6 seconds Three wiping cycles with washer spray Front wiper operation range move the wiper lever up down Rear wiper operation Washer ...

Page 463: ...udio Remote Control Switch POWER MODER SEEK SEEK MUTER VOL VOL Sun roof switch Main room lamp switch Front room lamp spot switch 1 2 3 Passenger s Heated Seat Switch Driver s Heated Seat Switch 4WD Control Switch Head Lamp Leveling Switch ...

Page 464: ...rs press it again Rear Fog Lamp Switch ESP OFF Switch If you press the ESP OFF switch the ESP function stops and the indicator lamp in instrument panel comes on Press this switch again to resume the ESP function At this time the indicator lamp goes out Driver s Power Window Switch Driver can controls all door windows Open Close Lock Unlock and doors Lock Unlock with this switch unit ...

Page 465: ... To choose a desired driving distance display mode press the switch Changing sequence ODO TRIP A TRIP B ODO Auto light position Front Wiper and Washer Coupled Operation Pull the lever briefly below 0 6 seconds One wiping cycle Pull and hold the lever for more than 0 6 seconds Three wiping cycles with washer spray Front wiper operation range move the wiper lever up down Rear wiper operation Washer ...

Page 466: ...udio Remote Control Switch POWER MODER SEEK SEEK MUTER VOL VOL Sun roof switch Main room lamp switch Front room lamp spot switch 1 2 3 Passenger s Heated Seat Switch Driver s Heated Seat Switch 4WD Control Switch Head Lamp Leveling Switch ...

Page 467: ...ons of manual wiper are as follows 1 Wiper function coupled auto washer When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid will be sprayed again and the wiper will automatically operate 3 times 2 Integrated auto light sensor in rain sensor unit The rain sensor unit is installed on a proper locat...

Page 468: ...r system uses the front washer fluid reservoir Because of this the washer hose is supposed to be long between front reservoir tank and rear washer nozzle To avoid being damaged or interfered while in assembling the vehicle the rear washer hose is fixed on headlining with silicone Rear washer hose and roof wiring harness are fixed at the headlining section with silicone ...

Page 469: ...d to change the spraying direction continuously according to the spraying time fan shape The figure below shows the changes of spraying direction according to the spraying time It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle The water may be entered into the engine compartment if the curved area of the engine hood and the nozzle is not adhered c...

Page 470: ...08 6 ACTYON 2006 03 7810 01 WIPER 2 SYSTEM LAYOUT OF WIPER AND WASHER WITH RAIN SENSOR ...

Page 471: ...08 7 WIPER ACTYON 2006 03 7810 01 ...

Page 472: ...08 8 ACTYON 2006 03 7810 01 WIPER 3 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 473: ...n 0 3 seconds after turning ON the washer switch for 0 1 0 59 seconds with the ignition key ON and it is turned off when the parking terminal is turned off 1 The wiper relay is turned on 0 3 seconds after turning ON the washer switch over 0 6 seconds with the ignition key ON and it is turned on three times immediately after turning off the washer switch 2 ...

Page 474: ...onds the operation in step 1 is performed 3 2 Rear Washer Motor Control When the rear washer switch is turn on with the ignition switch ON the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced...

Page 475: ...n the auto washer operation stops and the auto INT operation is activated 3 4 5 6 Priorities in Washer Operations The rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden...

Page 476: ...08 12 ACTYON 2006 03 7810 01 WIPER 4 WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM ...

Page 477: ...ons of manual wiper are as follows 1 Wiper function coupled auto washer When the front wiper switch is off and this switch is pressed washer fluid will be sprayed and the wiper will automatically operate 4 times Then the fluid will be sprayed again and the wiper will automatically operate 3 times 2 Integrated auto light sensor in rain sensor unit The rain sensor unit is installed on a proper locat...

Page 478: ...r system uses the front washer fluid reservoir Because of this the washer hose is supposed to be long between front reservoir tank and rear washer nozzle To avoid being damaged or interfered while in assembling the vehicle the rear washer hose is fixed on headlining with silicone Rear washer hose and roof wiring harness are fixed at the headlining section with silicone ...

Page 479: ...d to change the spraying direction continuously according to the spraying time fan shape The figure below shows the changes of spraying direction according to the spraying time It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle The water may be entered into the engine compartment if the curved area of the engine hood and the nozzle is not adhered c...

Page 480: ...08 6 ACTYON 2006 03 7810 01 WIPER 2 SYSTEM LAYOUT OF WIPER AND WASHER WITH RAIN SENSOR ...

Page 481: ...08 7 WIPER ACTYON 2006 03 7810 01 ...

Page 482: ...08 8 ACTYON 2006 03 7810 01 WIPER 3 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 483: ...n 0 3 seconds after turning ON the washer switch for 0 1 0 59 seconds with the ignition key ON and it is turned off when the parking terminal is turned off 1 The wiper relay is turned on 0 3 seconds after turning ON the washer switch over 0 6 seconds with the ignition key ON and it is turned on three times immediately after turning off the washer switch 2 ...

Page 484: ...onds the operation in step 1 is performed 3 2 Rear Washer Motor Control When the rear washer switch is turn on with the ignition switch ON the rear washer motor relay output is activated from the time when the rear washer switch is turned on and it is deactivated when the rear washer switch is turned off It cannot be activated while the front washer switch or the auto washer and wiper AFW Advanced...

Page 485: ...n the auto washer operation stops and the auto INT operation is activated 3 4 5 6 Priorities in Washer Operations The rear washer switch input is overridden during the front washer operation The rear washer switch input is overridden during the auto washer and wiper AFW operation The front washer switch input is overridden during the rear washer operation The auto washer switch input is overridden...

Page 486: ...08 12 ACTYON 2006 03 7810 01 WIPER 4 WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM ...

Page 487: ...e Multifunction Wiper Switch AUTO and Sensitivity Control A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor refer to the below picture AUTO Wiper operates automatically by rain sensor FAST S...

Page 488: ...wiper operation mode washer MIST AUTO then sends the information to the rain sensor STICS Engine Compartment Fuse Box Wiper relay HI Rear washer relay Front washer relay Wiper relay LO Auto Light Sensor and Rain Sensor Coupled Control Rain detected headlamp If it rains heavy which requires the intermediate INT speed the headlamps are turned on automatically Night detected wiping When the auto ligh...

Page 489: ...kes the wipers to operate automatically under the rain sensing mode multifunction switch wiper AUTO mode The emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain senso...

Page 490: ...o 2 are for communications between STICS and the rain sensor the No 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor No 2 terminal sends the wiper and washer operation information such as washer operation mode wiper relay or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in r...

Page 491: ...ardless of communication with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the INT auto switch to ON position from OFF position for the first tiime while the ignition key is in ON position When the wiper switch is turned to ON position again from OFF position the system drives the wiper motor through LOW relay one cycle only when the rain sensor det...

Page 492: ...g the washer switch input with the ignition switch ON and the auto INT switch ON in rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper operation 1 2 ...

Page 493: ... in AUTO position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal 1 If the volume sensitivity is changed more than 1 stage within 2 seconds the wiper motor runs only one cycle 4 Auto Light Control Only when the auto light switch is in AUTO position it controls the tail lamp and headlamp by communicating wi...

Page 494: ...y is in ON position and the INT switch is in ON position 1 The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity while the ignition key is in ON position and the INT switch is in ON position 2 The wiper mo...

Page 495: ...receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 1 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 2 ...

Page 496: ... requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 ...

Page 497: ...e Multifunction Wiper Switch AUTO and Sensitivity Control A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor refer to the below picture AUTO Wiper operates automatically by rain sensor FAST S...

Page 498: ...wiper operation mode washer MIST AUTO then sends the information to the rain sensor STICS Engine Compartment Fuse Box Wiper relay HI Rear washer relay Front washer relay Wiper relay LO Auto Light Sensor and Rain Sensor Coupled Control Rain detected headlamp If it rains heavy which requires the intermediate INT speed the headlamps are turned on automatically Night detected wiping When the auto ligh...

Page 499: ...kes the wipers to operate automatically under the rain sensing mode multifunction switch wiper AUTO mode The emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain senso...

Page 500: ...o 2 are for communications between STICS and the rain sensor the No 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor No 2 terminal sends the wiper and washer operation information such as washer operation mode wiper relay or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in r...

Page 501: ...ardless of communication with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the INT auto switch to ON position from OFF position for the first tiime while the ignition key is in ON position When the wiper switch is turned to ON position again from OFF position the system drives the wiper motor through LOW relay one cycle only when the rain sensor det...

Page 502: ...g the washer switch input with the ignition switch ON and the auto INT switch ON in rain sensing mode At this moment the communication with the rain sensor is overridden However the washer switch input is overridden during continuous operation The operation data is sent to the rain sensor even during the washer coupled wiper operation 1 2 ...

Page 503: ... in AUTO position and the wiper motor is in Parked position However the wiper motor can be operated only when the rain sensor detects the Rain Detected signal 1 If the volume sensitivity is changed more than 1 stage within 2 seconds the wiper motor runs only one cycle 4 Auto Light Control Only when the auto light switch is in AUTO position it controls the tail lamp and headlamp by communicating wi...

Page 504: ...y is in ON position and the INT switch is in ON position 1 The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity while the ignition key is in ON position and the INT switch is in ON position 2 The wiper mo...

Page 505: ...receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 1 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the INT switch is in ON position 2 ...

Page 506: ... requires the highest INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 ...

Page 507: ...creases as the obstacle approaches This supplementary system is to secure the safety distance for parking 1 Parking Aid Unit Detecting type Super sonic wave Detecting distance 25 cm 120 cm distance between sensor and obstacle 2 Parking Aid Sensor 1 Type Piezo ceramic element 2 Frequency 40 KHz 2 KHz 3 Detecting range 13 5 V Horizontal Min at cm Min at cm Vertical Min at cm Min at cm There is no up...

Page 508: ...p your parking operation Always keep the safety precautions Do not press or shock the sensors by hitting or high pressure water gun while washing or the sensors will be damaged If the system is in normal operating condition a short beep sounds when the gear selector lever is moved into R position with the ignition key ON If the system is in abnormal operating condition a beep sounds for 3 seconds ...

Page 509: ...ir braking noises from heavy commercial vehicles When a high power radio is turned on 3 Narrowed sensing area When the sensing portion is partially covered by snow or mud operates normally after cleaned Surrounding temperature of sensor is too high approx over 80 C or too low approx below 30 C 4 Not defective but may occur improper working When driving on the rough roads gravel road hill and grass...

Page 510: ...sure vertical and horizontal distance to obstacles When placing the gear selector lever to R position the designated unit PAS unit in the rear right quarter panel activates the parking aid sensors to measure the distance to obstacles PAS Related Devices Gear Selector Lever R Position Location of PAS Buzzer Unit PAS buzzer STICS PAS piezoelectric buzzer ...

Page 511: ...10 7 PAS ACTYON 2006 03 8790 03 Left Right Center Sensor Location Side Sensor Center Sensor PAS Sensor Parking Aid Unit The PAS unit is installed in the rear right section of the rear quarter panel ...

Page 512: ...nd display changes according to the distance as below While reversing if obstacles are within stage 1 the warning beep sounds with long intervals If within stage 2 the warning beep sounds with short intervals and if within stage 3 the warning beep sounds continuously ...

Page 513: ...and the data on failed sensor transmits to the instrument panel to light up the corresponding LED If normal the warning buzzer sounds only for 65 ms Whenever the power is applied the diagnosis mode is initiated Sensor failure conditions conditions for warning beep due to failure 1 2 Sensor failure conditions conditions for warning beep Open in sending circuit Open in receiving circuit Open in powe...

Page 514: ...10 10 ACTYON 2006 03 8790 03 PAS 4 CIRCUIT DIAGRAM ...

Page 515: ...creases as the obstacle approaches This supplementary system is to secure the safety distance for parking 1 Parking Aid Unit Detecting type Super sonic wave Detecting distance 25 cm 120 cm distance between sensor and obstacle 2 Parking Aid Sensor 1 Type Piezo ceramic element 2 Frequency 40 KHz 2 KHz 3 Detecting range 13 5 V Horizontal Min at cm Min at cm Vertical Min at cm Min at cm There is no up...

Page 516: ...p your parking operation Always keep the safety precautions Do not press or shock the sensors by hitting or high pressure water gun while washing or the sensors will be damaged If the system is in normal operating condition a short beep sounds when the gear selector lever is moved into R position with the ignition key ON If the system is in abnormal operating condition a beep sounds for 3 seconds ...

Page 517: ...ir braking noises from heavy commercial vehicles When a high power radio is turned on 3 Narrowed sensing area When the sensing portion is partially covered by snow or mud operates normally after cleaned Surrounding temperature of sensor is too high approx over 80 C or too low approx below 30 C 4 Not defective but may occur improper working When driving on the rough roads gravel road hill and grass...

Page 518: ...sure vertical and horizontal distance to obstacles When placing the gear selector lever to R position the designated unit PAS unit in the rear right quarter panel activates the parking aid sensors to measure the distance to obstacles PAS Related Devices Gear Selector Lever R Position Location of PAS Buzzer Unit PAS buzzer STICS PAS piezoelectric buzzer ...

Page 519: ...10 7 PAS ACTYON 2006 03 8790 03 Left Right Center Sensor Location Side Sensor Center Sensor PAS Sensor Parking Aid Unit The PAS unit is installed in the rear right section of the rear quarter panel ...

Page 520: ...nd display changes according to the distance as below While reversing if obstacles are within stage 1 the warning beep sounds with long intervals If within stage 2 the warning beep sounds with short intervals and if within stage 3 the warning beep sounds continuously ...

Page 521: ...and the data on failed sensor transmits to the instrument panel to light up the corresponding LED If normal the warning buzzer sounds only for 65 ms Whenever the power is applied the diagnosis mode is initiated Sensor failure conditions conditions for warning beep due to failure 1 2 Sensor failure conditions conditions for warning beep Open in sending circuit Open in receiving circuit Open in powe...

Page 522: ...10 10 ACTYON 2006 03 8790 03 PAS 4 CIRCUIT DIAGRAM ...

Page 523: ...0 3 AUDIO SYSTEM ACTYON 2006 03 8610 26 8930 01 AUDIO SYSTEM 1 AUDIO SYSTEM OVERVIEW Audio System 6 Speakers ...

Page 524: ...0 4 ACTYON 2006 03 8610 26 AUDIO SYSTEM 2 CIRCUIT DIAGRAM OF AUDIO SYSTEM ...

Page 525: ...0 3 AUDIO SYSTEM ACTYON 2006 03 8610 26 8930 01 AUDIO SYSTEM 1 AUDIO SYSTEM OVERVIEW Audio System 6 Speakers ...

Page 526: ...0 4 ACTYON 2006 03 8610 26 AUDIO SYSTEM 2 CIRCUIT DIAGRAM OF AUDIO SYSTEM ...

Page 527: ...02 3 ION 4 SPEED ACTYON 2006 03 3410 01 3640 01 ION 4 SPEED 1 SPECIFICATIONS ...

Page 528: ...02 4 ACTYON 2006 03 3410 01 ION 4 SPEED 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 529: ...he TCU utilizes throttle position rate of throttle opening engine speed vehicle speed transmission fluid temperature gear selector position and mode selector inputs and in some applications a Kickdown Switch to control all shift feel and shift schedule aspects The TCU drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects The output pressure o...

Page 530: ...02 6 ACTYON 2006 03 3410 01 ION 4 SPEED 2 APPEARANCE 1 4WD Automatic Transmission 2 2WD Automatic Transmission Torque converter Oil cooler return Servo Inhibiter switch Adapter housing Oil cooler outlet ...

Page 531: ...02 7 ION 4 SPEED ACTYON 2006 03 3410 01 3 SHIFT PATTERN DIAGRAM 1 Normal Mode WINTER mode has same shift pattern with NORMAL mode except 2nd gear drive off 2 Power Mode ...

Page 532: ...ugh the transmission in Neutral But the final drive is not locked by the parking pawl so thewheels are free to rotate D Overdrive range is used for all normal driving conditions 4th gear overdrive gear reduces the fuel consumption and the engine noise Engine braking is applied with reduced throttle First to second 1 2 first to third 1 3 second to third 2 3 second to fourth 2 4 third to fourth 3 4 ...

Page 533: ...ifts will occur to give maximum performance and the POWER mode indicator light is switched ON When WINTER mode is selected starting in second gear is facilitated the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF 3 Indicator Light The indicator light is located on the instrument panel Auto shift indicator light comes ON when the ignition switch ON and...

Page 534: ... electromagnetic solenoids Six of the seven solenoids are used to control the line pressure operate the shift valves and the torque converter lock up clutch and to turn ON and OFF the two regulator valves that control the shift feel The seventh solenoid is the proportional or Variable Pressure Solenoid VPS which works with the two regulator valves to control shift feel 1 Transmission Control Modul...

Page 535: ...djusts the variable pressure solenoid ramp pressure then executes the shift The TCU continuously monitors every input and output circuit for short or open circuits and operating range When a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and implements a Limp Home Mode LHM The actual limp home mode used depends upon the failure detected with ...

Page 536: ...the output shaft speed signal to the Engine Control Module ECM The information is then transferred to the TCU via the CAN Transmission Fluid Temperature The transmission fluid temperature sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission This sensor is a typical Negative Temperature Coefficient NTC resistor with low temperatures producing a high r...

Page 537: ...02 13 ION 4 SPEED ACTYON 2006 03 3410 01 ...

Page 538: ...Sensor 10 White Temperature Sensor 4 Gear position sensor The gear position sensor is incorporated in the inhibitor switch mounted on the side of the transmission case The gear position sensor is a multi function switch providing three functions Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral Illuminate the reverse lamps when Reverse is selected Ind...

Page 539: ... Battery voltage monitoring input The battery voltage monitoring input is connected to the positive side of the battery This signal is taken from the main supply to the TCU If the battery voltage at the TCU falls below 11 3 V the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited All other shifts are allowed but may not occur because of the reduce...

Page 540: ...N S4 switches the front band regulator valve OFF or ON S5 also provides the signal pressure for the converter clutch regulator valve Solenoid 5 S5 is a variable pressure solenoid that ramps the pressure during gear changes This solenoid provides the signal pressure to the clutch and band regulator thereby controlling the shift pressures S5 also provides the signal pressure for the converter clutch...

Page 541: ...02 17 ION 4 SPEED ACTYON 2006 03 3410 01 Solenoid Operation during Gearshifts ...

Page 542: ...n gear state and engine speed S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures VPS pressure is multiplexed to the clutch regulator valve the band regulator valve and the converter clutch regulator valve during automatic gearshifts A variable pressure solenoid produces a hydraulic pressur...

Page 543: ...lectrically controlled for each gearshift Mode indicator light Depending on the application the mode indicator light may be used to indicate the mode that has been selected or if an overheat condition exists The mode indicator light is usually located on the instrument cluster 9 Communication systems 1 CAN The Controller Area Network CAN connects various control modules by using a twisted pair of ...

Page 544: ...and at the same time causing the VPS to reach maximum pressure All downshifts are accomplished by switching VPS pressure to the band and or clutch regulator valve and sending a ramped current to the VPS The shift is completed by simultaneously switching the regulators OFF switching the shift valves and at the same time causing the VPS to return to stand by pressure The primary regulator valve is l...

Page 545: ...02 21 ION 4 SPEED ACTYON 2006 03 3410 01 1 Hydraulic Control Circuit ...

Page 546: ... into the PRND fluid circuits 1 2 shift valve The 1 2 shift valve is a two position valve that must be switched to the 2 3 and 4 position in order to get any forward gear other than first gear It is used for all 1 2 and 2 1 gearshifts The switching of this valve is achieved by using S1 and or S2 During a 1 2 gearshift drive oil from the manual valve passes through to the second gear circuit During...

Page 547: ...S1 which is located at the end of the valve spool During a 3 4 gearshift the 3 4 shift valve Exhausts the front band release B1R circuit thereby allowing the application of the front band B1 Connects the inner apply area of the front servo B1AI to the Band Apply Feed BAF circuit thus allowing greater apply forces to the front band Exhausts the Overrun Clutch OC circuit which allows the C4 clutch t...

Page 548: ...noid supply pressure regulator valve The solenoid supply pressure regulator valve supplies a constant pressure to all solenoids S1 to S7 Line pressure is used as the feeding oil to this regulator and the output is termed line 500 Line pressure control valve Line pressure is controlled by S6 which acts as the line pressure control valve When S6 pressure is applied to the end of the Primary Regulato...

Page 549: ...re of 2 25 times the S5 signal pressure when S3 is ON When S3 is OFF the output pressure is 2 25 times the line 500 pressure Band apply feed regulator valve The band apply feed regulator valve is a fixed ratio 1 4 1 valve It provides a regulated pressure to the front servo and controls the change rate of the front band B1 state to give the desired shift quality Second gear oil supplied to the valv...

Page 550: ...conditions are satisfied In P or N vehicle speed 3 km h In R vehicle speed 10 km h Engine speed 1600 rpm Throttle position 12 Under these conditions the TCU switches solenoids S1 and S2 to OFF The reverse lockout valve toggles under the influence of the S1 S2 pressure to connect the line pressure to the B2 feed Oil is fed to both the inner and outer apply areas of the rear servo piston applying B2...

Page 551: ...ecause all shifting pressures are controlled by separate band and clutch regulator valves and the output of S5 When reverse gear is selected both the low and high line pressure values are boosted to guard against slippage This is achieved by applying reverse oil line pressure to the PRV to assist the spring load The other end of the valve contains ports for line pressure feedback and S6 pressure T...

Page 552: ...clutch The switching of this valve is governed by the signal pressure from S7 When the valve is in the OFF or released position converter feed oil from the PRV is directed to the release side of the converter clutch After flowing through the converter oil returns to the converter clutch control valve and is then directed to the oil cooler When the valve is in the ON or applied position regulated o...

Page 553: ...t permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band B1 This prevents the needto force the oil back from the front servo through the valve body and through the 3 4 shift valve The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 kPa ...

Page 554: ...e operation of the Power Train System is detailed below First gear is engaged by applying the C2 clutch and locking the 1 2 One Way Clutch 1 2 OWC The 1 2 shift is accomplished by applying the B1 band and overrunning the 1 2 OWC The 2 3 shift is accomplished by applying the C1 clutch and releasing the B1 band The 3 4 shift is accomplished by re applying the B1 band and overrunning the 3 4 OWC Reve...

Page 555: ...02 31 ION 4 SPEED ACTYON 2006 03 3410 01 ...

Page 556: ...er and piston assembly en ables the torque converter to lock up under favorable conditions Lock up is only permitted to occur in third and fourth gears under specified throttle and vehicle speed conditions Lock up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover locking up the converter and eliminating unwanted slippage W...

Page 557: ...y occurs in reverse gear C4 CLUTCH When applied this clutch provides engine braking on overrun This occurs in Manual 1 2 and 3 and also Drive 2 and Drive 3 to prevent objectionable free wheel coasting Clutch packs Bands The transmission utilizes two bands the B1 band sometimes known as the 2 4 band and the B2 band sometimes known as the low reverse band The B1 band is a flexible band which is enga...

Page 558: ...etween the C4 and the C2 clutch assemblies This allows the C2 clutch to drive the forward sun gear in first second and third gears but unlocks in fourth gear and during overrun The B2 band is a solid band which is engaged by the rear servo piston B2 is activated in Park Reverse Neutral and Manual 1 When activated B2 prevents the planet carrier assembly from rotating In Manual 1 only the inner area...

Page 559: ...wer Flow Drive 4 Overdrive Power Flow Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case When Park is not selected a ret...

Page 560: ...02 36 ACTYON 2006 03 3410 01 ION 4 SPEED 1 Park And Neutral ...

Page 561: ... 2 Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pump pressure is applied to the Primary Regulator Valve PRV and to the solenoid supply pressure regulator valve The converter oil cooler and lubrication circuits are charged from the primary regulator valve The line 500 circuit is charged by the soleno...

Page 562: ...02 38 ACTYON 2006 03 3410 01 ION 4 SPEED 2 Reverse ...

Page 563: ... valve Reverse oil is routed from the manual valve to the C3 clutch Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the line pressure value All other clutch and band apply circuits are open to exhaust The elements of the transmission function as follows The C3 clutch is engaged and drives the reverse sun gear in a clock wise direction ...

Page 564: ...02 40 ACTYON 2006 03 3410 01 ION 4 SPEED 3 Manual 1 ...

Page 565: ... the inner apply area of the rear servo piston for B2 band application In Manual 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The B2 band is engaged to hold the planetary gear carrier stationary The forward sun gear drives the short pinion anticl...

Page 566: ...02 42 ACTYON 2006 03 3410 01 ION 4 SPEED 4 DRIVE 1 ...

Page 567: ...h In Drive 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under reaction forc...

Page 568: ...02 44 ACTYON 2006 03 3410 01 ION 4 SPEED 5 DRIVE 2 AND MANUAL 2 ...

Page 569: ...tch In Drive 2 and Manual 2 transmission drive is via the input shaft and forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under r...

Page 570: ...02 46 ACTYON 2006 03 3410 01 ION 4 SPEED 6 DRIVE 3 AND MANUAL 3 ...

Page 571: ... sun gear and the planet carrier are driven clockwise at the same speed therefore there is no relative motion between the sun gear and the pinions The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed The C4 clutch is applied to bypass the 3 4 OWC and provide engine braking on overrun The outer apply area of the front servo The 1 2 shift valve to provid...

Page 572: ...02 48 ACTYON 2006 03 3410 01 ION 4 SPEED ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 3 and Manual 3 x x x x ...

Page 573: ...02 49 ION 4 SPEED ACTYON 2006 03 3410 01 7 DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP ...

Page 574: ...N S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converte...

Page 575: ...02 51 ION 4 SPEED ACTYON 2006 03 3410 01 8 DRIVE 4 OVERDRIVE ...

Page 576: ...he reverse sun gear stationary As the planet carrier tuns the long pinion walks around the stationary reverse sun gear and rotates around its axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i e in overdrive ratio The forward sun gear is also driven faster than the input shaft and overruns the 3 4 OWC The C2 clutch is e...

Page 577: ...02 53 ION 4 SPEED ACTYON 2006 03 3410 01 ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 4 Overdrive x x x ...

Page 578: ...02 54 ACTYON 2006 03 3410 01 ION 4 SPEED 9 DRIVE 4 LOCK UP ...

Page 579: ... valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drived from drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converter clutch control valve Converter ...

Page 580: ...02 3 ION 4 SPEED ACTYON 2006 03 3410 01 3640 01 ION 4 SPEED 1 SPECIFICATIONS ...

Page 581: ...02 4 ACTYON 2006 03 3410 01 ION 4 SPEED 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 582: ...he TCU utilizes throttle position rate of throttle opening engine speed vehicle speed transmission fluid temperature gear selector position and mode selector inputs and in some applications a Kickdown Switch to control all shift feel and shift schedule aspects The TCU drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects The output pressure o...

Page 583: ...02 6 ACTYON 2006 03 3410 01 ION 4 SPEED 2 APPEARANCE 1 4WD Automatic Transmission 2 2WD Automatic Transmission Torque converter Oil cooler return Servo Inhibiter switch Adapter housing Oil cooler outlet ...

Page 584: ...02 7 ION 4 SPEED ACTYON 2006 03 3410 01 3 SHIFT PATTERN DIAGRAM 1 Normal Mode WINTER mode has same shift pattern with NORMAL mode except 2nd gear drive off 2 Power Mode ...

Page 585: ...ugh the transmission in Neutral But the final drive is not locked by the parking pawl so thewheels are free to rotate D Overdrive range is used for all normal driving conditions 4th gear overdrive gear reduces the fuel consumption and the engine noise Engine braking is applied with reduced throttle First to second 1 2 first to third 1 3 second to third 2 3 second to fourth 2 4 third to fourth 3 4 ...

Page 586: ...ifts will occur to give maximum performance and the POWER mode indicator light is switched ON When WINTER mode is selected starting in second gear is facilitated the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF 3 Indicator Light The indicator light is located on the instrument panel Auto shift indicator light comes ON when the ignition switch ON and...

Page 587: ... electromagnetic solenoids Six of the seven solenoids are used to control the line pressure operate the shift valves and the torque converter lock up clutch and to turn ON and OFF the two regulator valves that control the shift feel The seventh solenoid is the proportional or Variable Pressure Solenoid VPS which works with the two regulator valves to control shift feel 1 Transmission Control Modul...

Page 588: ...djusts the variable pressure solenoid ramp pressure then executes the shift The TCU continuously monitors every input and output circuit for short or open circuits and operating range When a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and implements a Limp Home Mode LHM The actual limp home mode used depends upon the failure detected with ...

Page 589: ...the output shaft speed signal to the Engine Control Module ECM The information is then transferred to the TCU via the CAN Transmission Fluid Temperature The transmission fluid temperature sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission This sensor is a typical Negative Temperature Coefficient NTC resistor with low temperatures producing a high r...

Page 590: ...02 13 ION 4 SPEED ACTYON 2006 03 3410 01 ...

Page 591: ...Sensor 10 White Temperature Sensor 4 Gear position sensor The gear position sensor is incorporated in the inhibitor switch mounted on the side of the transmission case The gear position sensor is a multi function switch providing three functions Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral Illuminate the reverse lamps when Reverse is selected Ind...

Page 592: ... Battery voltage monitoring input The battery voltage monitoring input is connected to the positive side of the battery This signal is taken from the main supply to the TCU If the battery voltage at the TCU falls below 11 3 V the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited All other shifts are allowed but may not occur because of the reduce...

Page 593: ...N S4 switches the front band regulator valve OFF or ON S5 also provides the signal pressure for the converter clutch regulator valve Solenoid 5 S5 is a variable pressure solenoid that ramps the pressure during gear changes This solenoid provides the signal pressure to the clutch and band regulator thereby controlling the shift pressures S5 also provides the signal pressure for the converter clutch...

Page 594: ...02 17 ION 4 SPEED ACTYON 2006 03 3410 01 Solenoid Operation during Gearshifts ...

Page 595: ...n gear state and engine speed S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures VPS pressure is multiplexed to the clutch regulator valve the band regulator valve and the converter clutch regulator valve during automatic gearshifts A variable pressure solenoid produces a hydraulic pressur...

Page 596: ...lectrically controlled for each gearshift Mode indicator light Depending on the application the mode indicator light may be used to indicate the mode that has been selected or if an overheat condition exists The mode indicator light is usually located on the instrument cluster 9 Communication systems 1 CAN The Controller Area Network CAN connects various control modules by using a twisted pair of ...

Page 597: ...and at the same time causing the VPS to reach maximum pressure All downshifts are accomplished by switching VPS pressure to the band and or clutch regulator valve and sending a ramped current to the VPS The shift is completed by simultaneously switching the regulators OFF switching the shift valves and at the same time causing the VPS to return to stand by pressure The primary regulator valve is l...

Page 598: ...02 21 ION 4 SPEED ACTYON 2006 03 3410 01 1 Hydraulic Control Circuit ...

Page 599: ... into the PRND fluid circuits 1 2 shift valve The 1 2 shift valve is a two position valve that must be switched to the 2 3 and 4 position in order to get any forward gear other than first gear It is used for all 1 2 and 2 1 gearshifts The switching of this valve is achieved by using S1 and or S2 During a 1 2 gearshift drive oil from the manual valve passes through to the second gear circuit During...

Page 600: ...S1 which is located at the end of the valve spool During a 3 4 gearshift the 3 4 shift valve Exhausts the front band release B1R circuit thereby allowing the application of the front band B1 Connects the inner apply area of the front servo B1AI to the Band Apply Feed BAF circuit thus allowing greater apply forces to the front band Exhausts the Overrun Clutch OC circuit which allows the C4 clutch t...

Page 601: ...noid supply pressure regulator valve The solenoid supply pressure regulator valve supplies a constant pressure to all solenoids S1 to S7 Line pressure is used as the feeding oil to this regulator and the output is termed line 500 Line pressure control valve Line pressure is controlled by S6 which acts as the line pressure control valve When S6 pressure is applied to the end of the Primary Regulato...

Page 602: ...re of 2 25 times the S5 signal pressure when S3 is ON When S3 is OFF the output pressure is 2 25 times the line 500 pressure Band apply feed regulator valve The band apply feed regulator valve is a fixed ratio 1 4 1 valve It provides a regulated pressure to the front servo and controls the change rate of the front band B1 state to give the desired shift quality Second gear oil supplied to the valv...

Page 603: ...conditions are satisfied In P or N vehicle speed 3 km h In R vehicle speed 10 km h Engine speed 1600 rpm Throttle position 12 Under these conditions the TCU switches solenoids S1 and S2 to OFF The reverse lockout valve toggles under the influence of the S1 S2 pressure to connect the line pressure to the B2 feed Oil is fed to both the inner and outer apply areas of the rear servo piston applying B2...

Page 604: ...ecause all shifting pressures are controlled by separate band and clutch regulator valves and the output of S5 When reverse gear is selected both the low and high line pressure values are boosted to guard against slippage This is achieved by applying reverse oil line pressure to the PRV to assist the spring load The other end of the valve contains ports for line pressure feedback and S6 pressure T...

Page 605: ...clutch The switching of this valve is governed by the signal pressure from S7 When the valve is in the OFF or released position converter feed oil from the PRV is directed to the release side of the converter clutch After flowing through the converter oil returns to the converter clutch control valve and is then directed to the oil cooler When the valve is in the ON or applied position regulated o...

Page 606: ...t permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band B1 This prevents the needto force the oil back from the front servo through the valve body and through the 3 4 shift valve The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 kPa ...

Page 607: ...e operation of the Power Train System is detailed below First gear is engaged by applying the C2 clutch and locking the 1 2 One Way Clutch 1 2 OWC The 1 2 shift is accomplished by applying the B1 band and overrunning the 1 2 OWC The 2 3 shift is accomplished by applying the C1 clutch and releasing the B1 band The 3 4 shift is accomplished by re applying the B1 band and overrunning the 3 4 OWC Reve...

Page 608: ...02 31 ION 4 SPEED ACTYON 2006 03 3410 01 ...

Page 609: ...er and piston assembly en ables the torque converter to lock up under favorable conditions Lock up is only permitted to occur in third and fourth gears under specified throttle and vehicle speed conditions Lock up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover locking up the converter and eliminating unwanted slippage W...

Page 610: ...y occurs in reverse gear C4 CLUTCH When applied this clutch provides engine braking on overrun This occurs in Manual 1 2 and 3 and also Drive 2 and Drive 3 to prevent objectionable free wheel coasting Clutch packs Bands The transmission utilizes two bands the B1 band sometimes known as the 2 4 band and the B2 band sometimes known as the low reverse band The B1 band is a flexible band which is enga...

Page 611: ...etween the C4 and the C2 clutch assemblies This allows the C2 clutch to drive the forward sun gear in first second and third gears but unlocks in fourth gear and during overrun The B2 band is a solid band which is engaged by the rear servo piston B2 is activated in Park Reverse Neutral and Manual 1 When activated B2 prevents the planet carrier assembly from rotating In Manual 1 only the inner area...

Page 612: ...wer Flow Drive 4 Overdrive Power Flow Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case When Park is not selected a ret...

Page 613: ...02 36 ACTYON 2006 03 3410 01 ION 4 SPEED 1 Park And Neutral ...

Page 614: ... 2 Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pump pressure is applied to the Primary Regulator Valve PRV and to the solenoid supply pressure regulator valve The converter oil cooler and lubrication circuits are charged from the primary regulator valve The line 500 circuit is charged by the soleno...

Page 615: ...02 38 ACTYON 2006 03 3410 01 ION 4 SPEED 2 Reverse ...

Page 616: ... valve Reverse oil is routed from the manual valve to the C3 clutch Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the line pressure value All other clutch and band apply circuits are open to exhaust The elements of the transmission function as follows The C3 clutch is engaged and drives the reverse sun gear in a clock wise direction ...

Page 617: ...02 40 ACTYON 2006 03 3410 01 ION 4 SPEED 3 Manual 1 ...

Page 618: ... the inner apply area of the rear servo piston for B2 band application In Manual 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The B2 band is engaged to hold the planetary gear carrier stationary The forward sun gear drives the short pinion anticl...

Page 619: ...02 42 ACTYON 2006 03 3410 01 ION 4 SPEED 4 DRIVE 1 ...

Page 620: ...h In Drive 1 transmission drive is via the input shaft to the forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under reaction forc...

Page 621: ...02 44 ACTYON 2006 03 3410 01 ION 4 SPEED 5 DRIVE 2 AND MANUAL 2 ...

Page 622: ...tch In Drive 2 and Manual 2 transmission drive is via the input shaft and forward clutch cylinder The elements of the transmission function as follows The C2 clutch is engaged to drive the forward sun gear via the 3 4 OWC The forward sun gear drives the short pinion anticlockwise The short pinion drives the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under r...

Page 623: ...02 46 ACTYON 2006 03 3410 01 ION 4 SPEED 6 DRIVE 3 AND MANUAL 3 ...

Page 624: ... sun gear and the planet carrier are driven clockwise at the same speed therefore there is no relative motion between the sun gear and the pinions The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed The C4 clutch is applied to bypass the 3 4 OWC and provide engine braking on overrun The outer apply area of the front servo The 1 2 shift valve to provid...

Page 625: ...02 48 ACTYON 2006 03 3410 01 ION 4 SPEED ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 3 and Manual 3 x x x x ...

Page 626: ...02 49 ION 4 SPEED ACTYON 2006 03 3410 01 7 DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP ...

Page 627: ...N S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converte...

Page 628: ...02 51 ION 4 SPEED ACTYON 2006 03 3410 01 8 DRIVE 4 OVERDRIVE ...

Page 629: ...he reverse sun gear stationary As the planet carrier tuns the long pinion walks around the stationary reverse sun gear and rotates around its axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i e in overdrive ratio The forward sun gear is also driven faster than the input shaft and overruns the 3 4 OWC The C2 clutch is e...

Page 630: ...02 53 ION 4 SPEED ACTYON 2006 03 3410 01 ELEMENTS ENGAGED Gear State C1 C1 C1 C1 B1 B1 1 2 OWC 3 4 OWC LU CLUTCH Drive 4 Overdrive x x x ...

Page 631: ...02 54 ACTYON 2006 03 3410 01 ION 4 SPEED 9 DRIVE 4 LOCK UP ...

Page 632: ... valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drived from drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is exhausted at the converter clutch control valve Converter ...

Page 633: ...ed to prevent incorrect shifting To improve the shifting performance 3 piece double cone is used for 1 2 shift 2 3 The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 4 TSM54 52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement The clutch release ...

Page 634: ...03 4 ACTYON 2006 03 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications ...

Page 635: ...03 5 M T ACTYON 2006 03 3170 01 2 Tightening Torque ...

Page 636: ...03 6 ACTYON 2006 03 3170 01 M T Inside N Switch 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch 0 5mm 0 5mm ...

Page 637: ...etection The gear lever is at a position other than neutral N switch detection Start the vehicle while depressing the clutch pedal Clutch switch detection The RPM increases in accordance with the temperature of the engine coolant Engine coolant temperature sensor detection appx 100 rpm increase appx 100 170 rpm increase appx 80 C normal temperature of the engine coolant around 200 rpm When the gea...

Page 638: ...itch transmits information to the ECU through the CAN communication while New Rexton is connected to the ECU through wires Thus if you set the variant coding in the engine ECU you must do it differently and you must set the variant coding differently according to the vehicle category and specification as below Neutral Signal Input None Wire CAN Wire Actyon Kyron models with manual transmission New...

Page 639: ......

Page 640: ...ed to prevent incorrect shifting To improve the shifting performance 3 piece double cone is used for 1 2 shift 2 3 The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 4 TSM54 52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement The clutch release ...

Page 641: ...03 4 ACTYON 2006 03 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications ...

Page 642: ...03 5 M T ACTYON 2006 03 3170 01 2 Tightening Torque ...

Page 643: ...03 6 ACTYON 2006 03 3170 01 M T Inside N Switch 1 MANUAL TRANSMISSION SYSTEM 1 Neutral Switch Outside N Switch N Neutral Switch 0 5mm 0 5mm ...

Page 644: ...etection The gear lever is at a position other than neutral N switch detection Start the vehicle while depressing the clutch pedal Clutch switch detection The RPM increases in accordance with the temperature of the engine coolant Engine coolant temperature sensor detection appx 100 rpm increase appx 100 170 rpm increase appx 80 C normal temperature of the engine coolant around 200 rpm When the gea...

Page 645: ...itch transmits information to the ECU through the CAN communication while New Rexton is connected to the ECU through wires Thus if you set the variant coding in the engine ECU you must do it differently and you must set the variant coding differently according to the vehicle category and specification as below Neutral Signal Input None Wire CAN Wire Actyon Kyron models with manual transmission New...

Page 646: ......

Page 647: ...04 3 CLUTCH ACTYON 2006 03 3010 01 1 CLUTCH SPECIFICATIONS 2 TIGHTENING TORQUE 3020 01 CLUTCH ...

Page 648: ...justs the clutch freeplay according to the wear of clutch disc 2 Operation description Internal Components of Clutch Cover Disc wear Free play Diaphragm spring 1 Adjusting equipment 2 3 Pressure plate 4 Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so pressure plate is pushed to clutch disc side at the amount of wear ...

Page 649: ...the input shaft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consists of the clutch pedal and clutch release cylinder This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the c...

Page 650: ...04 6 ACTYON 2006 03 3010 01 CLUTCH Components of Clutch Assembly Concentric Slave Cylinder Clutch Assembly 3 Functions Adapter Pipe Assembly ...

Page 651: ...04 7 CLUTCH ACTYON 2006 03 3010 01 Cross Sectional View of Clutch Assembly 1 Transmission housing 4 Bolt 2 Clutch disc assembly 5 Washer 3 Clutch disc cover assembly 6 Bolt ...

Page 652: ...04 3 CLUTCH ACTYON 2006 03 3010 01 1 CLUTCH SPECIFICATIONS 2 TIGHTENING TORQUE 3020 01 CLUTCH ...

Page 653: ...justs the clutch freeplay according to the wear of clutch disc 2 Operation description Internal Components of Clutch Cover Disc wear Free play Diaphragm spring 1 Adjusting equipment 2 3 Pressure plate 4 Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so pressure plate is pushed to clutch disc side at the amount of wear ...

Page 654: ...the input shaft The driving and driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly Operating Elements The clutch release system consists of the clutch pedal and clutch release cylinder This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the c...

Page 655: ...04 6 ACTYON 2006 03 3010 01 CLUTCH Components of Clutch Assembly Concentric Slave Cylinder Clutch Assembly 3 Functions Adapter Pipe Assembly ...

Page 656: ...04 7 CLUTCH ACTYON 2006 03 3010 01 Cross Sectional View of Clutch Assembly 1 Transmission housing 4 Bolt 2 Clutch disc assembly 5 Washer 3 Clutch disc cover assembly 6 Bolt ...

Page 657: ...05 3 AXLE ACTYON 2006 03 4120 01 4120 01 AXLE 1 SPECIFICATIONS OF AXLE 1 Front View 2 Rear View 3 Specifications ...

Page 658: ...2006 03 4120 01 AXLE 4 specifications of front and rear axle The specification below is for front and rear axles equipped in Actyon including gear ratio and specific specifications For details refer to each section ...

Page 659: ...05 5 AXLE ACTYON 2006 03 4120 01 1 OVERVIEW OF AXLE 1 Front Axle 2 Rear Axle ...

Page 660: ...05 3 AXLE ACTYON 2006 03 4120 01 4120 01 AXLE 1 SPECIFICATIONS OF AXLE 1 Front View 2 Rear View 3 Specifications ...

Page 661: ...2006 03 4120 01 AXLE 4 specifications of front and rear axle The specification below is for front and rear axles equipped in Actyon including gear ratio and specific specifications For details refer to each section ...

Page 662: ...05 5 AXLE ACTYON 2006 03 4120 01 1 OVERVIEW OF AXLE 1 Front Axle 2 Rear Axle ...

Page 663: ...lows 1 Delete 4L LOW 4WD Delete the planetary gear reduction hub and shift fork Add the coupling according to the deletion of the planetary gear 2 No additional coding is required when replacing TCCU Delete the devices tone wheel wiring etc related to the speed sensor in the transfer case 3 This system receives the speed signals from ABS ESP HECU or instrument panel for non ABS vehicle Note 1 thro...

Page 664: ...03 3240 01 TRANSFER CASE 1 STRUCTURE Front axle Front locking hub system IWE Power steering assembly Front propeller shaft ION 4th gear automatic transmission Part time transfer case TCCU Rear propeller shaft Rear axle ...

Page 665: ...Transfer case main connector Shift motor connector Rear propeller shaft Transfer case assembly Oil drain plug Tightening torque 19 30 Nm Front propeller shaft Oil filler plug Tightening torque 19 30 Nm Magnet clutch power supply connector for 1 pin T C motor Damper ...

Page 666: ...ION 1 System Layout 4WD switch Shifting to 4H mode to 4H direction Shifting to 2H mode to 2H direction I P 4WD indicator Shifting to 4H mode 4WD HIGH comes on Shifting to 2H mode 4WD HIGH goes off System defective 4WD CHECK comes on TCCU Solenoid valve Magnetic clutch ...

Page 667: ... locking hub that is applied to Kyron uses the IWE Integrated Wheel End system and in this system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Atmosphere Atmosphere Electrical signal Booster Vacuum modulator for engine ...

Page 668: ...hub gear In 4WD mode the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve Hub actuator LH 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear 4WD releasing vacuum pressure from hub actuator The vacuum pressure is released ...

Page 669: ...0 9 TRANSFER CASE ACTYON 2006 03 3240 01 4 POWER FLOW 1 Components of Power Flow Part time transfer case Transfer case Engine Rear 2WD Rear wheel side Front 4WD Front wheel side ...

Page 670: ...0 10 ACTYON 2006 03 3240 01 TRANSFER CASE 2 Flow Layout ...

Page 671: ...0 11 TRANSFER CASE ACTYON 2006 03 3240 01 3 2H Mode Rear Wheel Drive 1 Layout ...

Page 672: ...0 12 ACTYON 2006 03 3240 01 TRANSFER CASE 4 4H Mode 4 Wheel Drive High speed 1 Layout ...

Page 673: ...lows 1 Delete 4L LOW 4WD Delete the planetary gear reduction hub and shift fork Add the coupling according to the deletion of the planetary gear 2 No additional coding is required when replacing TCCU Delete the devices tone wheel wiring etc related to the speed sensor in the transfer case 3 This system receives the speed signals from ABS ESP HECU or instrument panel for non ABS vehicle Note 1 thro...

Page 674: ...03 3240 01 TRANSFER CASE 1 STRUCTURE Front axle Front locking hub system IWE Power steering assembly Front propeller shaft ION 4th gear automatic transmission Part time transfer case TCCU Rear propeller shaft Rear axle ...

Page 675: ...Transfer case main connector Shift motor connector Rear propeller shaft Transfer case assembly Oil drain plug Tightening torque 19 30 Nm Front propeller shaft Oil filler plug Tightening torque 19 30 Nm Magnet clutch power supply connector for 1 pin T C motor Damper ...

Page 676: ...ION 1 System Layout 4WD switch Shifting to 4H mode to 4H direction Shifting to 2H mode to 2H direction I P 4WD indicator Shifting to 4H mode 4WD HIGH comes on Shifting to 2H mode 4WD HIGH goes off System defective 4WD CHECK comes on TCCU Solenoid valve Magnetic clutch ...

Page 677: ... locking hub that is applied to Kyron uses the IWE Integrated Wheel End system and in this system the vacuum is generated only within the hub actuator It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Atmosphere Atmosphere Electrical signal Booster Vacuum modulator for engine ...

Page 678: ...hub gear In 4WD mode the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve Hub actuator LH 2WD applying vacuum pressure to hub actuator The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear 4WD releasing vacuum pressure from hub actuator The vacuum pressure is released ...

Page 679: ...0 9 TRANSFER CASE ACTYON 2006 03 3240 01 4 POWER FLOW 1 Components of Power Flow Part time transfer case Transfer case Engine Rear 2WD Rear wheel side Front 4WD Front wheel side ...

Page 680: ...0 10 ACTYON 2006 03 3240 01 TRANSFER CASE 2 Flow Layout ...

Page 681: ...0 11 TRANSFER CASE ACTYON 2006 03 3240 01 3 2H Mode Rear Wheel Drive 1 Layout ...

Page 682: ...0 12 ACTYON 2006 03 3240 01 TRANSFER CASE 4 4H Mode 4 Wheel Drive High speed 1 Layout ...

Page 683: ...07 3 SUSPENSION ACTYON 2006 03 4411 01 4510 01 SUSPENSION 1 SPECIFICATIONS OF SUSPENSION 2 WHEEL ALIGNMENT ...

Page 684: ...07 3 SUSPENSION ACTYON 2006 03 4411 01 4510 01 SUSPENSION 1 SPECIFICATIONS OF SUSPENSION 2 WHEEL ALIGNMENT ...

Page 685: ...iffer between ABS ESP system equipped vehicle and non ABS ESP equipped vehicle The drum type brake is installed on non ABS equipped vehicle while the solid disc thickness approx 10 4 mm is installed on ABS ESP equipped vehicle 3 Parking Brake Ventilated disc type Solid disc type Front Ventilated Disc and Caliper 2 internal Cylinders Piston Rear Disc and Caliper 1 Internal Cylinder For the parking ...

Page 686: ...08 4 ACTYON 2006 03 4892 01 ESP 2 SECTIONAL DRAWING 1 Front Disc Brake 2 Rear Disc Brake ...

Page 687: ...o signal the vehicle speed to the engine ECU TCCU transmission and instrument panel There is no separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication 1 Location of the wheel speed sensor rear right wheel Connector Appearance In vehicle...

Page 688: ...08 6 ACTYON 2006 03 4892 01 ESP 3 SPECIFICATIONS Description Item NON ABS ABS ESP Brake pedal Brake master cylinder Brake booster Front brake Rear brake Parking brake Brake fluid ...

Page 689: ...does not imply any problems with the brake system Phenomenon 2 Slip or screech after the brake pad replacement This usually occurs when the bed in is not made between the disc and the pad s friction material The bed in is a state that the brake system normally works and gives no noise out when after about 300 km city driving the contact area of the pad friction material is enlarged and the disk is...

Page 690: ...ary device for comfortable driving When the vehicle exceeds its physical limits it cannot be controlled Do not rely on the system Keep on the safe driving Feeling when ESP is working When the ESP system activates the feeling can be different depending on vehicle driving conditions For example you will feel differently when the ESP system is activated during the ABS is operating with the brakes app...

Page 691: ...he vehicle rollover by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills over 10 ESP HECU HDC Switch Indicator Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic Brake Force Dist...

Page 692: ...itch ESP warning lamp comes on ESP is activated by pressing the switch again ESP warning lamp goes off HDC is activated by pressing the switch Green HDC indicator comes on HDC is deactivated by pressing the switch again Green HDC indicator goes off Detects the angle of the steering wheel and sends it to HECU Detects lateral acceleration longitudinal acceleration and yaw rate ...

Page 693: ...892 01 Wheel Speed Sensor FOR 4WD Rear Wheel Speed Sensor LH RH HECU Receives the signals from wheel speed sensor steering wheel angle sensor sensor cluster and pressure sensor and perform the vehicle stability control function ...

Page 694: ... during cornering by controlling the vehicle stability using the input values from the sensors and applying the brakes independently to the corresponding wheels The system also controls during cornering by detecting the moment right before the spin and automatically limiting the engine output coupled with the ASR system Understeering is when the steering wheel is steered to a certain angle during ...

Page 695: ...ain angle during driving and the rear tires slip outward losing traction When compared with under steering vehicles the controlling of the vehicle is difficult during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases 2 Over steering ...

Page 696: ...er the vehicle as he or she intends 2 ESP Control As the single track vehicle model used for the calculations is only valid for a vehicle moving forward ESP intervention never takes place during backup The ESP system includes the ABS EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions For example when the brakes are applied during cornering at ...

Page 697: ...08 15 ESP ACTYON 2006 03 4892 01 The following figure shows the operating range according to driving conditions Operating range Turning Turning ...

Page 698: ...ols by ESP system under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 699: ...ng is required under emergency The BAS System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the...

Page 700: ... that emergency braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depresses the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated Operating conditions Pressure over 20 bar Pressure changes over...

Page 701: ... needed One must note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sha...

Page 702: ...quently the vehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane The ARP function is activated when the vehicle is subject to turning over due to sharp cornering even when the ESP function is turned off however the ARP function is also deactivated when the ESP function is not operatable due to system malfunction ...

Page 703: ...lope level exceeding 10 through a separately installed switch operation When the vehicle speed reaches below 7 km h refer to the information below the HDC automatically terminates the operation When you press the HDC switch the green HDC indicator comes on and when the HDC operates the green HDC indictor flashes at 0 5 second of interval The G Sensor within the sensor cluster detects the steepness...

Page 704: ... effect during downhill driving on a steep hill For manual transmission equipped vehicle HDC system should operated only in 1st gear 3 When not depressing the accelerator pedal or brake pedal 4 The vehicle speed is above 7 km h in Automatic transmission 4H mode and and The vehicle speed given in step 4 varies according to the vehicle driving mode and the speed ranges by the vehicle driving mode an...

Page 705: ...10 and 20 during the HDC operation When depressing the accelerator pedal or brake pedal HDC system is changed to stand by mode When releasing the pedal HDC starts its operation again Therefore drivers can control the vehicle speed to a desired level by depressing and releasing the pedal When the slope level exceeds 20 during the HDC operation When depressing the accelerator pedal HDC system is cha...

Page 706: ...r unit When the vehicle speed is out of the specified values under 7 km h 3 When the ESP related functions e g vehicle position control BAS ARP is activated during HDC operation 4 The HDC is the device to improve the engine brake effect during downhill driving on a steep hill If the ESP function is in operation HDC operation is overridden When the internal temperature of HDC system goes over due t...

Page 707: ...TYON 2006 03 4892 01 4 Input Output Signals for HDC Operation The HDC controller operates its function in the HECU inside the ESP unit and receives the following signals to perform the hill descent control function ...

Page 708: ...ment panel has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Basically the brake system apos s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON...

Page 709: ...in HDC operation The HDC system is intended for use only on off roads with a slope level exceeding 10 Thus do not use it on public road Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems Driver must turn the HDC switch to OFF position when driving on public and level roads As mentioned previously when a driver make sharp turns or drive on rough roads the H...

Page 710: ...pressure sensor Active Wheel Speed Sensor 7 Components And Locations There are no major changes in the ESP system of ACTYON comparing to the conventional ESP system However the HDC switch and the HDC indicator has been added to the system as the HDC system has been applied ...

Page 711: ... 29 ESP ACTYON 2006 03 4892 01 Steering Wheel Angle Sensor HDC Switch Sensor Cluster Yaw Rate Lateral Sensor Longitudinal Sensor ESP OFF Switch HDC Indicator ABS ESP Indicator 1 Comparison with ABS System ...

Page 712: ...08 30 ACTYON 2006 03 4892 01 ESP 7 INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM Input Output of ESP System ...

Page 713: ...08 31 ESP ACTYON 2006 03 4892 01 8 HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ...

Page 714: ...in primary circuit and in secondary circuit When the vehicle brakes are not applied during engine running or when applying the non ABS operating brakes the normally open separation valve and the inlet valve are open whereas the normally closed shuttle valve and the outlet valve are closed When the ESP system is operating the normally open separation valve will be closed by the solenoid valve opera...

Page 715: ...e are closed When the brake is applied under these conditions the brake fluid will be sent to each wheel via the separation valve and inlet valve The pressure decreases just before the wheel speed drops and the wheels are locked The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the...

Page 716: ...sing the valves the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuou...

Page 717: ...king depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the whee...

Page 718: ...Speed Sensor Front Wheel Speed Sensor for 4WD 11 COMPONENTS OF ABS SYSTEM The following figure shows the basic system components of the ABS This system consists of HECU valve body and ECU integrated type front wheel speed sensor and rear wheel speed sensor Valve body B Plunger C Cam bushing Motor pump ...

Page 719: ...08 37 ESP ACTYON 2006 03 4892 01 1 Input and Output Diagram of ABS System ...

Page 720: ...ont wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 721: ... to close the inlet valve and stop the hydraulic pressure increases At this moment the outlet valve is closed This procedure helps the wheel to maintain a stable hydraulic pressure 2 3 Pressure Decreases in the Circuit when ABS is Operating Even when the hydraulic pressure on each circuit is stable the wheel can be locked as the wheel speed decreases This is when the ABS ECU detects the wheel spee...

Page 722: ...lates to the wheel by the pump no pressure increase in wheel Therefore when depressing the brake pedal the pressure generated in the master cylinder is transferred to the disc and then the outlet valve decreases this pressure intermittently This operation continues repetitively until there are no signs that the ABS ECU is locking the wheels When the ABS hydraulic pressure control takes place there...

Page 723: ...iffer between ABS ESP system equipped vehicle and non ABS ESP equipped vehicle The drum type brake is installed on non ABS equipped vehicle while the solid disc thickness approx 10 4 mm is installed on ABS ESP equipped vehicle 3 Parking Brake Ventilated disc type Solid disc type Front Ventilated Disc and Caliper 2 internal Cylinders Piston Rear Disc and Caliper 1 Internal Cylinder For the parking ...

Page 724: ...08 4 ACTYON 2006 03 4892 01 ESP 2 SECTIONAL DRAWING 1 Front Disc Brake 2 Rear Disc Brake ...

Page 725: ...o signal the vehicle speed to the engine ECU TCCU transmission and instrument panel There is no separate unit to process the wheel speed sensor signal The wheel speed sensor is connected to the engine ECU terminal 36 where its signal is processed and is connected to other related systems through CAN communication 1 Location of the wheel speed sensor rear right wheel Connector Appearance In vehicle...

Page 726: ...08 6 ACTYON 2006 03 4892 01 ESP 3 SPECIFICATIONS Description Item NON ABS ABS ESP Brake pedal Brake master cylinder Brake booster Front brake Rear brake Parking brake Brake fluid ...

Page 727: ...does not imply any problems with the brake system Phenomenon 2 Slip or screech after the brake pad replacement This usually occurs when the bed in is not made between the disc and the pad s friction material The bed in is a state that the brake system normally works and gives no noise out when after about 300 km city driving the contact area of the pad friction material is enlarged and the disk is...

Page 728: ...ary device for comfortable driving When the vehicle exceeds its physical limits it cannot be controlled Do not rely on the system Keep on the safe driving Feeling when ESP is working When the ESP system activates the feeling can be different depending on vehicle driving conditions For example you will feel differently when the ESP system is activated during the ABS is operating with the brakes app...

Page 729: ...he vehicle rollover by quickly and firmly controlling the engine output and the brake The HDC Hill Descent Control is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills over 10 ESP HECU HDC Switch Indicator Functions applied on ESP system are as follows 1 ABS Anti Lock Brake System 2 EBD Electronic Brake Force Dist...

Page 730: ...itch ESP warning lamp comes on ESP is activated by pressing the switch again ESP warning lamp goes off HDC is activated by pressing the switch Green HDC indicator comes on HDC is deactivated by pressing the switch again Green HDC indicator goes off Detects the angle of the steering wheel and sends it to HECU Detects lateral acceleration longitudinal acceleration and yaw rate ...

Page 731: ...892 01 Wheel Speed Sensor FOR 4WD Rear Wheel Speed Sensor LH RH HECU Receives the signals from wheel speed sensor steering wheel angle sensor sensor cluster and pressure sensor and perform the vehicle stability control function ...

Page 732: ... during cornering by controlling the vehicle stability using the input values from the sensors and applying the brakes independently to the corresponding wheels The system also controls during cornering by detecting the moment right before the spin and automatically limiting the engine output coupled with the ASR system Understeering is when the steering wheel is steered to a certain angle during ...

Page 733: ...ain angle during driving and the rear tires slip outward losing traction When compared with under steering vehicles the controlling of the vehicle is difficult during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases 2 Over steering ...

Page 734: ...er the vehicle as he or she intends 2 ESP Control As the single track vehicle model used for the calculations is only valid for a vehicle moving forward ESP intervention never takes place during backup The ESP system includes the ABS EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions For example when the brakes are applied during cornering at ...

Page 735: ...08 15 ESP ACTYON 2006 03 4892 01 The following figure shows the operating range according to driving conditions Operating range Turning Turning ...

Page 736: ...ols by ESP system under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 737: ...ng is required under emergency The BAS System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the...

Page 738: ... that emergency braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depresses the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated Operating conditions Pressure over 20 bar Pressure changes over...

Page 739: ... needed One must note that the ARP system just as general assistant devices including the ABS is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power Following picture shows how the ARP compensates the vehicle position by varying each wheel s braking power to overcome the physical tendency of the vehicle rollover during sha...

Page 740: ...quently the vehicle speed decreases rapidly so the driver must take caution for the vehicle may drift away from the lane The ARP function is activated when the vehicle is subject to turning over due to sharp cornering even when the ESP function is turned off however the ARP function is also deactivated when the ESP function is not operatable due to system malfunction ...

Page 741: ...lope level exceeding 10 through a separately installed switch operation When the vehicle speed reaches below 7 km h refer to the information below the HDC automatically terminates the operation When you press the HDC switch the green HDC indicator comes on and when the HDC operates the green HDC indictor flashes at 0 5 second of interval The G Sensor within the sensor cluster detects the steepness...

Page 742: ... effect during downhill driving on a steep hill For manual transmission equipped vehicle HDC system should operated only in 1st gear 3 When not depressing the accelerator pedal or brake pedal 4 The vehicle speed is above 7 km h in Automatic transmission 4H mode and and The vehicle speed given in step 4 varies according to the vehicle driving mode and the speed ranges by the vehicle driving mode an...

Page 743: ...10 and 20 during the HDC operation When depressing the accelerator pedal or brake pedal HDC system is changed to stand by mode When releasing the pedal HDC starts its operation again Therefore drivers can control the vehicle speed to a desired level by depressing and releasing the pedal When the slope level exceeds 20 during the HDC operation When depressing the accelerator pedal HDC system is cha...

Page 744: ...r unit When the vehicle speed is out of the specified values under 7 km h 3 When the ESP related functions e g vehicle position control BAS ARP is activated during HDC operation 4 The HDC is the device to improve the engine brake effect during downhill driving on a steep hill If the ESP function is in operation HDC operation is overridden When the internal temperature of HDC system goes over due t...

Page 745: ...TYON 2006 03 4892 01 4 Input Output Signals for HDC Operation The HDC controller operates its function in the HECU inside the ESP unit and receives the following signals to perform the hill descent control function ...

Page 746: ...ment panel has two modes green function lamp and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation Basically the brake system apos s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on when Initial ignition ON...

Page 747: ...in HDC operation The HDC system is intended for use only on off roads with a slope level exceeding 10 Thus do not use it on public road Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems Driver must turn the HDC switch to OFF position when driving on public and level roads As mentioned previously when a driver make sharp turns or drive on rough roads the H...

Page 748: ...pressure sensor Active Wheel Speed Sensor 7 Components And Locations There are no major changes in the ESP system of ACTYON comparing to the conventional ESP system However the HDC switch and the HDC indicator has been added to the system as the HDC system has been applied ...

Page 749: ... 29 ESP ACTYON 2006 03 4892 01 Steering Wheel Angle Sensor HDC Switch Sensor Cluster Yaw Rate Lateral Sensor Longitudinal Sensor ESP OFF Switch HDC Indicator ABS ESP Indicator 1 Comparison with ABS System ...

Page 750: ...08 30 ACTYON 2006 03 4892 01 ESP 7 INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM Input Output of ESP System ...

Page 751: ...08 31 ESP ACTYON 2006 03 4892 01 8 HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ...

Page 752: ...in primary circuit and in secondary circuit When the vehicle brakes are not applied during engine running or when applying the non ABS operating brakes the normally open separation valve and the inlet valve are open whereas the normally closed shuttle valve and the outlet valve are closed When the ESP system is operating the normally open separation valve will be closed by the solenoid valve opera...

Page 753: ...e are closed When the brake is applied under these conditions the brake fluid will be sent to each wheel via the separation valve and inlet valve The pressure decreases just before the wheel speed drops and the wheels are locked The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the...

Page 754: ...sing the valves the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuou...

Page 755: ...king depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve will stay closed When the whee...

Page 756: ...Speed Sensor Front Wheel Speed Sensor for 4WD 11 COMPONENTS OF ABS SYSTEM The following figure shows the basic system components of the ABS This system consists of HECU valve body and ECU integrated type front wheel speed sensor and rear wheel speed sensor Valve body B Plunger C Cam bushing Motor pump ...

Page 757: ...08 37 ESP ACTYON 2006 03 4892 01 1 Input and Output Diagram of ABS System ...

Page 758: ...ont wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 759: ... to close the inlet valve and stop the hydraulic pressure increases At this moment the outlet valve is closed This procedure helps the wheel to maintain a stable hydraulic pressure 2 3 Pressure Decreases in the Circuit when ABS is Operating Even when the hydraulic pressure on each circuit is stable the wheel can be locked as the wheel speed decreases This is when the ABS ECU detects the wheel spee...

Page 760: ...lates to the wheel by the pump no pressure increase in wheel Therefore when depressing the brake pedal the pressure generated in the master cylinder is transferred to the disc and then the outlet valve decreases this pressure intermittently This operation continues repetitively until there are no signs that the ABS ECU is locking the wheels When the ABS hydraulic pressure control takes place there...

Page 761: ...essure to operate the power steering system The pressure relief valve in the pump controls the discharging pressure The rotary control valve in the rack and pinion gear directs the oil from the power steering pump to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie ...

Page 762: ...09 4 ACTYON 2006 03 4610 01 POWER STEERING 1 SYSTEM LAYOUT ...

Page 763: ...09 5 POWER STEERING ACTYON 2006 03 4610 01 ...

Page 764: ...09 6 ACTYON 2006 03 4610 01 POWER STEERING 2 COMPONENTS ...

Page 765: ...09 7 POWER STEERING ACTYON 2006 03 4610 01 ...

Page 766: ...essure to operate the power steering system The pressure relief valve in the pump controls the discharging pressure The rotary control valve in the rack and pinion gear directs the oil from the power steering pump to one side of the rack piston The integrated rack piston converts the hydraulic pressure to linear movement The operating force of the rack moves the wheels through the tie rod the tie ...

Page 767: ...09 4 ACTYON 2006 03 4610 01 POWER STEERING 1 SYSTEM LAYOUT ...

Page 768: ...09 5 POWER STEERING ACTYON 2006 03 4610 01 ...

Page 769: ...09 6 ACTYON 2006 03 4610 01 POWER STEERING 2 COMPONENTS ...

Page 770: ...09 7 POWER STEERING ACTYON 2006 03 4610 01 ...

Page 771: ...gs deploy and the seat belt pretensioners of the driver s and passenger s seat belts retract seat belts 1 2 Curtain air bag G sensors These are located inside the left and right B pillar panel bottoms When a collision occurs the air bag at the side of collision deploys accordingly Please pay attention to that in the case of the curtain air bag only the air bag at the side of collision deploys not ...

Page 772: ... after receiving the air bag deployment signal at the vehicle speed 3 km h or higher it sends out the door UNLOCK signal for 5 seconds Inflator Gas guide Air bag cable Curtain air bag collision G sensor BPT Belt Pretensioner 1 LOCATIONS AND RELATED COMPONENTS Curtain air bag DAB Driver Air Bag ...

Page 773: ... driver s and passenger s air bags and or the driver s and passenger s seat belt retensioners When the front collision G sensor sends out only the air bag deployment signal the signal deploys the two front air bags and ctivates their seat belt pretensioners LH RH Connector Inflator Gas guide Curtain air bag Gas guide Inflator Air bag cable Curtain air bag collision G sensor BPT Belt Pretensioner ...

Page 774: ...ON PROCESS The overall air bag operation process and its functions and roles are broadly explained in this block diagram This diagram summarizes and highlights the functions adopted by Ssangyoung Motors 1 Air Bag System Block Diagram Functions and Roles Included ...

Page 775: ...02 7 AIR BAG ACTYON 2006 03 8810 03 ...

Page 776: ... from vehicle collision the detonation is fired by the electrical signal of the air bag unit Then the detonation sets off explosives and nitrogen gas is generated At this point the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver Rear View 1 Components Front View Air bag cover Air bag housing Air bag cushion approx 50 liters Inflator appr...

Page 777: ...e to operate together When the collision G sensor inside the air bag unit sends a collision signal the air bag unit instantaneously applies a high current to the driver s and passenger s air bags and the seat belt pretensioners on both seats fires the detonator in the inflator and inflates the air bag cushions curtain air bags independently operate in case of the side collisions Rear View Front Vi...

Page 778: ...ic of the curtain air bag is slightly different from the one of the front air bag including pretensioner but it is the same as the conventional side air bag A collision situation is detected by the curtain air bag collision G sensor installed at the lower side of the B pillar The signal is transmitted to the air bag unit The air bag unit instantly inflates the necessary air bag necessary by sendin...

Page 779: ...02 11 AIR BAG ACTYON 2006 03 8810 03 1 Components ...

Page 780: ...hen the front air bags deploy When a collision occurs or when brakes are applied a seat belt with a pretensioner detects the stopping action and tightens the belt before the wearer is propelled forward This holds the occupant more securely in the seat Belt Pretensioner Driver Side Belt Pretensioner Passenger Side Belt pretensioner LH Curtain air bag G sensor Belt pretensioner RH ...

Page 781: ...tensioner reel assembly Reel bracket Ring upper stay D ring Bending tongue Tongue stopper Mini anchor D bolt Washer Fiber washer Rivet ID label Plastic washer Steel washer D bolt Label D bolt Spacer Bush Mini anchor cover 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 782: ...CTYON 2006 03 8810 03 AIR BAG 5 Air Bag Unit Air Bag Unit connector The sensor that detects collision is integrated into the air bag unit Air bag unit is installed under the AV head unit in center fascia panel ...

Page 783: ...enger s seats that is around the pretensioner reel The body panel has guiding holes to ensure its correct installation But incorrect tightening torque may break the sensor or make it insecure As a result the sensor may have inaccurate judgment and have the air bag deployed inaccurately connetor Driver s Side Passenger s Side Signal terminal Ground ...

Page 784: ...ch fires the detonator in the inflator This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for firing Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance The detonator may explode due to a sudden extra power supplied by the tester Before removing or installing any air bag re...

Page 785: ...ned off in the middle of the unlock signal being sent out the unlock signal continues for the remaining time This function cancels when the ignition key is withdrawn 1 2 3 4 Reminder for door lock unlock control The unlock function by the air bag signal takes priority over any other lock unlock operations While or after the automatic unlock is made by the air bag system any lock or unlock request ...

Page 786: ...lashing it six times the air bag warning lamp will turn off if no malfunction have been detected 2 When the Air Bag Unit Detects Any Malfunctions in Unit When it is recorded as a system failure in the air bag unit the air bag warning lamp on the instrument panel comes on for about 6 seconds and goes off for 1 second Then the waning lamp stays on 3 When the Air Bag Unit Receives Any Malfunction Sig...

Page 787: ...02 19 AIR BAG ACTYON 2006 03 8810 03 10 ELECTRICAL WIRING DIAGRAM ...

Page 788: ... 1 COMPOSITION OF SEAT 1 Driver Seat Reclining Motor Seat Cushion Rear Area Up Down Motor Seat Cushion Front Area Up Down Motor Lumbar Support Lever Seat cushion rear area up down bar Sliding rail Seat cushion front area up down bar Sliding motor Sliding rail ...

Page 789: ...03 4 ACTYON 2006 03 7410 01 SEAT 2 Passenger Seat Reclining Motor Power Seat Switch Sliding rail Sliding rail Sliding motor Reclining Switch Sliding lever No seat height control function ...

Page 790: ...n moves up or down 2 Seat Cushion Angle Adjustment When moving the front side of the seat cushion switch up or down the front side of the seat cushion moves up or down When moving the rear side of the switch up or down the rear side of the seat cushion moves up or down 3 Seatback Reclining Adjustment When moving the upper side of the reclining switch forward or rearward the seatback moves forward ...

Page 791: ...e headrest pull it up without pressing the release button To lower the headrest press the release button 1 on top of seatback and push the headrest down To change the seatback angle push the lever rearward Then release the lever at the desired position The seat is locked at the position Seatback Reclining Lever Seatback Reclining Lever ...

Page 792: ...rotect occupant s face and chest when a strong frontal collision occurs Seat Belt in Front Seats 3 point type Seat Belt in Rear Seat 3 Point Type LH RH Seat Belt in Rear Seat 2 3Point Type Center Seat Belt Seat belt anchor Seat belt height adjustment lever Seat belt D ring Pre tensioner Seat belt anchor Seat Belt Seat belt D ring Buckle of 3 point type seat belt Buckle of 2 point type seat belt Bu...

Page 793: ... 1 COMPOSITION OF SEAT 1 Driver Seat Reclining Motor Seat Cushion Rear Area Up Down Motor Seat Cushion Front Area Up Down Motor Lumbar Support Lever Seat cushion rear area up down bar Sliding rail Seat cushion front area up down bar Sliding motor Sliding rail ...

Page 794: ...03 4 ACTYON 2006 03 7410 01 SEAT 2 Passenger Seat Reclining Motor Power Seat Switch Sliding rail Sliding rail Sliding motor Reclining Switch Sliding lever No seat height control function ...

Page 795: ...n moves up or down 2 Seat Cushion Angle Adjustment When moving the front side of the seat cushion switch up or down the front side of the seat cushion moves up or down When moving the rear side of the switch up or down the rear side of the seat cushion moves up or down 3 Seatback Reclining Adjustment When moving the upper side of the reclining switch forward or rearward the seatback moves forward ...

Page 796: ...e headrest pull it up without pressing the release button To lower the headrest press the release button 1 on top of seatback and push the headrest down To change the seatback angle push the lever rearward Then release the lever at the desired position The seat is locked at the position Seatback Reclining Lever Seatback Reclining Lever ...

Page 797: ...rotect occupant s face and chest when a strong frontal collision occurs Seat Belt in Front Seats 3 point type Seat Belt in Rear Seat 3 Point Type LH RH Seat Belt in Rear Seat 2 3Point Type Center Seat Belt Seat belt anchor Seat belt height adjustment lever Seat belt D ring Pre tensioner Seat belt anchor Seat Belt Seat belt D ring Buckle of 3 point type seat belt Buckle of 2 point type seat belt Bu...

Page 798: ...04 3 SUNROOF ACTYON 2006 03 7340 01 7340 01 SUNROOF 1 COMPONENTS AND LOCATIONS Sunroof Switch Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Front Drain Hose Rear Drain Hose ...

Page 799: ...itch clockwise OPEN direction for less than 0 5 seconds the sunroof slides back and opens until it reaches at the 1st stop position 330 mm Then if you continue to rotate the switch to its stop the sunroof is fully opened 420 mm To stop the operation while moving operate the sunroof switch to any direction 2 Close To fully close the sunroof briefly for approx 0 5 sec rotate the sunroof switch count...

Page 800: ... operation and the sunroof goes back to the original position However if the force against the sunroof is less than the specified value or the continuous resistance is detected the Anti Trap function doesn t operate Therefore make sure that there is no obstacle such as hand head or part of body before operating the sunroof 4 Hazard Manual Operation The sunroof can be operated by rotating the screw...

Page 801: ...04 6 ACTYON 2006 03 7340 01 SUNROOF 6 Circuit Diagram of Sunroof ...

Page 802: ...04 3 SUNROOF ACTYON 2006 03 7340 01 7340 01 SUNROOF 1 COMPONENTS AND LOCATIONS Sunroof Switch Sunroof Motor Sunroof Control Unit SCU Sunroof Assembly Front Drain Hose Rear Drain Hose ...

Page 803: ...itch clockwise OPEN direction for less than 0 5 seconds the sunroof slides back and opens until it reaches at the 1st stop position 330 mm Then if you continue to rotate the switch to its stop the sunroof is fully opened 420 mm To stop the operation while moving operate the sunroof switch to any direction 2 Close To fully close the sunroof briefly for approx 0 5 sec rotate the sunroof switch count...

Page 804: ... operation and the sunroof goes back to the original position However if the force against the sunroof is less than the specified value or the continuous resistance is detected the Anti Trap function doesn t operate Therefore make sure that there is no obstacle such as hand head or part of body before operating the sunroof 4 Hazard Manual Operation The sunroof can be operated by rotating the screw...

Page 805: ...04 6 ACTYON 2006 03 7340 01 SUNROOF 6 Circuit Diagram of Sunroof ...

Page 806: ...1 LOCATIONS Instrument Panel Instrument Lower Panel Driver Side Glove Box and Instrument Lower Panel Passenger Side Sun Visor A Pillar B Pillar D Pillar C Pillar Quarter Panel Instrument Panel Assembly C Pillar D Pillar and Rear Quarter Panel Center Console Assembly ...

Page 807: ...05 3 BODY INTERIOR ACTYON 2006 03 7610 01 Interior Room Lamp Sun Visor Front Room Lamp A Pillar B Pillar Door Trim Front Door Rear Door Trim Headlining Assembly Roof Wiring Rear Washer Hose ...

Page 808: ...1 LOCATIONS Instrument Panel Instrument Lower Panel Driver Side Glove Box and Instrument Lower Panel Passenger Side Sun Visor A Pillar B Pillar D Pillar C Pillar Quarter Panel Instrument Panel Assembly C Pillar D Pillar and Rear Quarter Panel Center Console Assembly ...

Page 809: ...05 3 BODY INTERIOR ACTYON 2006 03 7610 01 Interior Room Lamp Sun Visor Front Room Lamp A Pillar B Pillar Door Trim Front Door Rear Door Trim Headlining Assembly Roof Wiring Rear Washer Hose ...

Page 810: ...Y EXTERIOR 1 COMPOSITION OF BODY EXTERIOR Hood Assembly Sunroof Assembly Front Door Assembly Front Bumper Assembly Cover Front end member lower Energy absorber Front bumper Front bumper fascia assembly Headlamp Front extension cover Front Fender Assembly ...

Page 811: ...XTERIOR Rear Door Assembly Tailgate Assembly Rear Bumper Assembly Side sill garnish Fog light type Dummy type Fog light type Rear bumper fascia assembly Rear bumper garnish Energy absorber Rear bumper Rear bumper beam Rear upper bracket ...

Page 812: ...Y EXTERIOR 1 COMPOSITION OF BODY EXTERIOR Hood Assembly Sunroof Assembly Front Door Assembly Front Bumper Assembly Cover Front end member lower Energy absorber Front bumper Front bumper fascia assembly Headlamp Front extension cover Front Fender Assembly ...

Page 813: ...XTERIOR Rear Door Assembly Tailgate Assembly Rear Bumper Assembly Side sill garnish Fog light type Dummy type Fog light type Rear bumper fascia assembly Rear bumper garnish Energy absorber Rear bumper Rear bumper beam Rear upper bracket ...

Page 814: ...07 3 BODY REPAIR ACTYON 2006 03 4110 01 4110 01 BODY REPAIR 1 DIMENSIONS ...

Page 815: ...07 4 ACTYON 2006 03 4110 01 BODY REPAIR 2 JACK UP POINTS ...

Page 816: ...Dash Panel and Engine Tunnel with Foaming Pad Blocks the noise from engine and transmission and improves the reinforcement of vehicle body Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision ...

Page 817: ... Body Panel Reinforcement Sealer to the Door Outer Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise BPR sealer to reinforce the body panel and reduce the noise Door impact beam reinforcement to reinforce the door impact beam Door impact beam to protect the passengers in case of side collision ...

Page 818: ...07 7 BODY REPAIR ACTYON 2006 03 4110 01 4 Applied BPR Body Panel Reinforcement Sealer to the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise ...

Page 819: ...07 8 ACTYON 2006 03 4110 01 BODY REPAIR 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 820: ......

Page 821: ...07 3 BODY REPAIR ACTYON 2006 03 4110 01 4110 01 BODY REPAIR 1 DIMENSIONS ...

Page 822: ...07 4 ACTYON 2006 03 4110 01 BODY REPAIR 2 JACK UP POINTS ...

Page 823: ...Dash Panel and Engine Tunnel with Foaming Pad Blocks the noise from engine and transmission and improves the reinforcement of vehicle body Dash panel Deadening sheet Dash reinforcement Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision ...

Page 824: ... Body Panel Reinforcement Sealer to the Door Outer Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise BPR sealer to reinforce the body panel and reduce the noise Door impact beam reinforcement to reinforce the door impact beam Door impact beam to protect the passengers in case of side collision ...

Page 825: ...07 7 BODY REPAIR ACTYON 2006 03 4110 01 4 Applied BPR Body Panel Reinforcement Sealer to the Body Panel BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise ...

Page 826: ...07 8 ACTYON 2006 03 4110 01 BODY REPAIR 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 827: ......

Page 828: ...tom of engine compartment This changes the air source mode by detecting the air pollution and the ambient temperature A function that turns on off the air source selection and air quality system Compressor AQS Switch Manual air conditioner FATC AQS sensor Ambient tempera ture sensor Sun Sensor Instrument Panel Upper Left It changes sun load coming through front windshield into current to input to ...

Page 829: ...ment Panel Air conditioner controller Mode door actuator Air mix door actuator Coolant temperature sensor Air source door actuator Air conditioner filter Thermo AMP Main wiring connector Power transistor Blower Unit Side Heater Unit Side Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly Detects A C switch position coolant temperature engine condition and driving condi...

Page 830: ...01 4 ACTYON 2006 03 6810 20 AIR CONDITIONER 2 VENTILATION SYSTEM 1 Locations of Vents 2 Air Duct ...

Page 831: ...ensor Thermo AMP Power transistor Blower motor Air source door actuator Coolant temperature sensor Air mix door actuator Coolant temperature detection sensor Air source door actuator Power transistor Blower motor Air conditioner controller unit Thermo AMP Air mix door actuator Main wire connector Active incar sensor interior temperature sensor and humidity sensor Mode door actuator ...

Page 832: ...rmo AMP Coolant Temperature Sensor Mode Door Actuator Power Transistor Blower Motor Air Conditioner Filter Air Source Door Actuator 3 AIR CONDITIONER MODULE AND SENSORS 1 Locations A C Controller Unit Active incar and humidity sensor Power transistor Blower motor Air mix door actuator ...

Page 833: ...01 7 AIR CONDITIONER ACTYON 2006 03 6810 20 2 Components ...

Page 834: ...01 8 ACTYON 2006 03 6810 20 AIR CONDITIONER 3 PTC Heater and FFH Heater Layout 1 PTC Heater Assembly Layout 2 FFH Heater Assembly Layout ...

Page 835: ...igerant pressure ambient temperature and condenser temperature to protect air conditioner circuits However for the vehicle equipped with DI engine the engine ECU turns off air conditioner compressor as below in addition to above conditions Coolant temperature below Coolant temperature over For approx 4 seconds after starting the engine When engine speed is below 650 rpm When engine speed is over 4...

Page 836: ......

Page 837: ...tom of engine compartment This changes the air source mode by detecting the air pollution and the ambient temperature A function that turns on off the air source selection and air quality system Compressor AQS Switch Manual air conditioner FATC AQS sensor Ambient tempera ture sensor Sun Sensor Instrument Panel Upper Left It changes sun load coming through front windshield into current to input to ...

Page 838: ...ment Panel Air conditioner controller Mode door actuator Air mix door actuator Coolant temperature sensor Air source door actuator Air conditioner filter Thermo AMP Main wiring connector Power transistor Blower Unit Side Heater Unit Side Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly Detects A C switch position coolant temperature engine condition and driving condi...

Page 839: ...01 4 ACTYON 2006 03 6810 20 AIR CONDITIONER 2 VENTILATION SYSTEM 1 Locations of Vents 2 Air Duct ...

Page 840: ...ensor Thermo AMP Power transistor Blower motor Air source door actuator Coolant temperature sensor Air mix door actuator Coolant temperature detection sensor Air source door actuator Power transistor Blower motor Air conditioner controller unit Thermo AMP Air mix door actuator Main wire connector Active incar sensor interior temperature sensor and humidity sensor Mode door actuator ...

Page 841: ...rmo AMP Coolant Temperature Sensor Mode Door Actuator Power Transistor Blower Motor Air Conditioner Filter Air Source Door Actuator 3 AIR CONDITIONER MODULE AND SENSORS 1 Locations A C Controller Unit Active incar and humidity sensor Power transistor Blower motor Air mix door actuator ...

Page 842: ...01 7 AIR CONDITIONER ACTYON 2006 03 6810 20 2 Components ...

Page 843: ...01 8 ACTYON 2006 03 6810 20 AIR CONDITIONER 3 PTC Heater and FFH Heater Layout 1 PTC Heater Assembly Layout 2 FFH Heater Assembly Layout ...

Page 844: ...igerant pressure ambient temperature and condenser temperature to protect air conditioner circuits However for the vehicle equipped with DI engine the engine ECU turns off air conditioner compressor as below in addition to above conditions Coolant temperature below Coolant temperature over For approx 4 seconds after starting the engine When engine speed is below 650 rpm When engine speed is over 4...

Page 845: ......

Page 846: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 847: ......

Page 848: ...0 3 ECU GASOLINE ACTYON 2006 03 0000 00 0000 00 ECU GASOLINE 1 ECU GASOLINE ...

Page 849: ...0 4 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 850: ...0 5 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 851: ...0 6 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 852: ...0 7 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 853: ...0 8 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 854: ...0 9 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 855: ...0 10 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 856: ...0 11 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 857: ...0 12 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 858: ...0 13 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 859: ...0 14 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 860: ...0 15 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 861: ...0 16 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 862: ...0 17 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 863: ...0 18 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 864: ...0 19 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 865: ...0 20 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 866: ...0 21 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 867: ...0 22 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 868: ...0 23 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 869: ...0 24 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 870: ...0 25 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 871: ...0 26 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 872: ...0 27 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 873: ...0 28 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 874: ...0 29 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 875: ...0 30 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 876: ...0 31 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 877: ...0 32 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 878: ...0 33 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 879: ...0 34 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 880: ...0 35 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 881: ...0 36 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 882: ...0 37 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 883: ...0 38 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 884: ...0 39 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 885: ...0 40 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 886: ...0 41 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 887: ...0 42 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 888: ...0 43 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 889: ...0 44 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 890: ...0 45 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 891: ...0 46 ACTYON 2006 03 0000 00 ECU GASOLINE ...

Page 892: ...0 47 ECU GASOLINE ACTYON 2006 03 0000 00 ...

Page 893: ......

Page 894: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 895: ......

Page 896: ...0 3 ECU DIESEL ACTYON 2006 03 0000 00 0000 00 ECU DIESEL 1 ECU DIESEL ...

Page 897: ...0 4 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 898: ...0 5 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 899: ...0 6 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 900: ...0 7 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 901: ...0 8 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 902: ...0 9 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 903: ...0 10 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 904: ...0 11 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 905: ...0 12 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 906: ...0 13 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 907: ...0 14 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 908: ...0 15 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 909: ...0 16 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 910: ...0 17 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 911: ...0 18 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 912: ...0 19 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 913: ...0 20 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 914: ...0 21 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 915: ...0 22 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 916: ...0 23 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 917: ...0 24 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 918: ...0 25 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 919: ...0 26 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 920: ...0 27 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 921: ...0 28 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 922: ...0 29 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 923: ...0 30 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 924: ...0 31 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 925: ...0 32 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 926: ...0 33 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 927: ...0 34 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 928: ...0 35 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 929: ...0 36 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 930: ...0 37 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 931: ...0 38 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 932: ...0 39 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 933: ...0 40 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 934: ...0 41 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 935: ...0 42 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 936: ...0 43 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 937: ...0 44 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 938: ...0 45 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 939: ...0 46 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 940: ...0 47 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 941: ...0 48 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 942: ...0 49 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 943: ...0 50 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 944: ...0 51 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 945: ...0 52 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 946: ...0 53 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 947: ...0 54 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 948: ...0 55 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 949: ...0 56 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 950: ...0 57 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 951: ...0 58 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 952: ...0 59 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 953: ...0 60 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 954: ...0 61 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 955: ...0 62 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 956: ...0 63 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 957: ...0 64 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 958: ...0 65 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 959: ...0 66 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 960: ...0 67 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 961: ...0 68 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 962: ...0 69 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 963: ...0 70 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 964: ...0 71 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 965: ...0 72 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 966: ...0 73 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 967: ...0 74 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 968: ...0 75 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 969: ...0 76 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 970: ...0 77 ECU DIESEL ACTYON 2006 03 0000 00 ...

Page 971: ...0 78 ACTYON 2006 03 0000 00 ECU DIESEL ...

Page 972: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 973: ......

Page 974: ...0 3 BRAKE ACTYON 2006 03 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 975: ...0 4 ACTYON 2006 03 0000 00 BRAKE ...

Page 976: ...0 5 BRAKE ACTYON 2006 03 0000 00 ...

Page 977: ...0 6 ACTYON 2006 03 0000 00 BRAKE ...

Page 978: ...0 7 BRAKE ACTYON 2006 03 0000 00 ...

Page 979: ...0 8 ACTYON 2006 03 0000 00 BRAKE ...

Page 980: ...0 9 BRAKE ACTYON 2006 03 0000 00 ...

Page 981: ...0 10 ACTYON 2006 03 0000 00 BRAKE ...

Page 982: ...0 11 BRAKE ACTYON 2006 03 0000 00 ...

Page 983: ...0 12 ACTYON 2006 03 0000 00 BRAKE ...

Page 984: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 985: ......

Page 986: ...0 3 BRAKE ACTYON 2006 03 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 987: ...0 4 ACTYON 2006 03 0000 00 BRAKE ...

Page 988: ...0 5 BRAKE ACTYON 2006 03 0000 00 ...

Page 989: ...0 6 ACTYON 2006 03 0000 00 BRAKE ...

Page 990: ...0 7 BRAKE ACTYON 2006 03 0000 00 ...

Page 991: ...0 8 ACTYON 2006 03 0000 00 BRAKE ...

Page 992: ...0 9 BRAKE ACTYON 2006 03 0000 00 ...

Page 993: ...0 10 ACTYON 2006 03 0000 00 BRAKE ...

Page 994: ...0 11 BRAKE ACTYON 2006 03 0000 00 ...

Page 995: ...0 12 ACTYON 2006 03 0000 00 BRAKE ...

Page 996: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 997: ......

Page 998: ...0 3 AIR BAG ACTYON 2006 03 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 999: ...0 4 ACTYON 2006 03 0000 00 AIR BAG ...

Page 1000: ...0 5 AIR BAG ACTYON 2006 03 0000 00 ...

Page 1001: ...0 6 ACTYON 2006 03 0000 00 AIR BAG ...

Page 1002: ...0 7 AIR BAG ACTYON 2006 03 0000 00 ...

Page 1003: ...0 8 ACTYON 2006 03 0000 00 AIR BAG ...

Page 1004: ...0 9 AIR BAG ACTYON 2006 03 0000 00 ...

Page 1005: ...0 10 ACTYON 2006 03 0000 00 AIR BAG ...

Page 1006: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 1007: ......

Page 1008: ...0 3 CCCS ACTYON 2006 03 0000 00 0000 00 CCCS 1 CCCS ...

Page 1009: ...0 4 ACTYON 2006 03 0000 00 CCCS ...

Page 1010: ...0 5 CCCS ACTYON 2006 03 0000 00 ...

Page 1011: ...0 6 ACTYON 2006 03 0000 00 CCCS ...

Page 1012: ...0 7 CCCS ACTYON 2006 03 0000 00 ...

Page 1013: ...0 8 ACTYON 2006 03 0000 00 CCCS ...

Page 1014: ...0 9 CCCS ACTYON 2006 03 0000 00 ...

Page 1015: ...0 10 ACTYON 2006 03 0000 00 CCCS ...

Page 1016: ...0 11 CCCS ACTYON 2006 03 0000 00 ...

Page 1017: ...0 12 ACTYON 2006 03 0000 00 CCCS ...

Page 1018: ...0 13 CCCS ACTYON 2006 03 0000 00 ...

Page 1019: ...0 14 ACTYON 2006 03 0000 00 CCCS ...

Page 1020: ...0 15 CCCS ACTYON 2006 03 0000 00 ...

Page 1021: ...0 16 ACTYON 2006 03 0000 00 CCCS ...

Page 1022: ...0 17 CCCS ACTYON 2006 03 0000 00 ...

Page 1023: ...0 18 ACTYON 2006 03 0000 00 CCCS ...

Page 1024: ...0 19 CCCS ACTYON 2006 03 0000 00 ...

Page 1025: ...0 20 ACTYON 2006 03 0000 00 CCCS ...

Page 1026: ...0 21 CCCS ACTYON 2006 03 0000 00 ...

Page 1027: ...0 22 ACTYON 2006 03 0000 00 CCCS ...

Page 1028: ...0 23 CCCS ACTYON 2006 03 0000 00 ...

Page 1029: ...0 24 ACTYON 2006 03 0000 00 CCCS ...

Page 1030: ...0 25 CCCS ACTYON 2006 03 0000 00 ...

Page 1031: ...0 26 ACTYON 2006 03 0000 00 CCCS ...

Page 1032: ...0 27 CCCS ACTYON 2006 03 0000 00 ...

Page 1033: ......

Page 1034: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 1035: ......

Page 1036: ...ATC 1 SELF DIAGNOSIS 1 Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds Check LED segments on the vacuum fluorescent display VFD Press OFF switch more than 5 seconds ...

Page 1037: ...he digit 2 is displayed implying step 2 on the display window and the trouble diagnosis for sensors is executed If no failure exists 20 is displayed If any failure exists the appropriate trouble code is displayed as below Trouble Code The symbol in front of step number 2 means a short circuit of the blinking sensor Short circuit in the ambient air temperature sensor ...

Page 1038: ...EMP dial to the right to set in the trouble diagnosis step 3 Indication of Step 2 Starting self diagnosis Sensor failure code blinking 30 no failure Trouble Code 4 Set in Trouble Diagnosis Step 4 In this step check the position of actuator door check the fan speed and check the compressor operation Slightly turn the TEMP switch in step 3 until 41 is displayed on the display window When pressing DE...

Page 1039: ...mbient air temperature Interior air temperature Intake air temperature Press Press Press 6 Set in Trouble Diagnosis Step 6 In this step the temperature can be compensated within the range of 3 C to 3 C in the control process according to the temperature to air conditioner controller The step 6 initiates when slightly rotating the fan speed switch other than TEMP switch in step 5 Step 6 Min tempera...

Page 1040: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 1041: ......

Page 1042: ...0 3 FFH ACTYON 2006 03 0000 00 0000 00 FFH 1 FFH ...

Page 1043: ...0 4 ACTYON 2006 03 0000 00 FFH ...

Page 1044: ...0 5 FFH ACTYON 2006 03 0000 00 ...

Page 1045: ...0 6 ACTYON 2006 03 0000 00 FFH ...

Page 1046: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 1047: ......

Page 1048: ...0 3 FFH ACTYON 2006 03 0000 00 0000 00 FFH 1 FFH ...

Page 1049: ...0 4 ACTYON 2006 03 0000 00 FFH ...

Page 1050: ...0 5 FFH ACTYON 2006 03 0000 00 ...

Page 1051: ...0 6 ACTYON 2006 03 0000 00 FFH ...

Page 1052: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 1053: ......

Page 1054: ...0 3 P TRUNK ACTYON 2006 03 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 1055: ...0 4 ACTYON 2006 03 0000 00 P TRUNK ...

Page 1056: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 1057: ......

Page 1058: ...0 3 P TRUNK ACTYON 2006 03 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 1059: ...0 4 ACTYON 2006 03 0000 00 P TRUNK ...

Page 1060: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 1061: ......

Page 1062: ...erminals in the ICM box 1 2 It rains but the system does not work in the AUTO position Symptom 2 Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops Therefore change the knob to the low sensitivity The wiper operates 3 or 4 times at high speed abruptly Symptom 3...

Page 1063: ...he wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 1064: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 1065: ......

Page 1066: ...erminals in the ICM box 1 2 It rains but the system does not work in the AUTO position Symptom 2 Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops Therefore change the knob to the low sensitivity The wiper operates 3 or 4 times at high speed abruptly Symptom 3...

Page 1067: ...he wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 1068: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 1069: ......

Page 1070: ...0 3 STICS ACTYON 2006 03 0000 00 0000 00 STICS 1 STICS ...

Page 1071: ...0 4 ACTYON 2006 03 0000 00 STICS ...

Page 1072: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 1073: ......

Page 1074: ...0 3 TC ACTYON 2006 03 0000 00 0000 00 TC 1 TC ...

Page 1075: ...0 4 ACTYON 2006 03 0000 00 TC ...

Page 1076: ...0 5 TC ACTYON 2006 03 0000 00 ...

Page 1077: ...0 6 ACTYON 2006 03 0000 00 TC ...

Page 1078: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 1079: ......

Page 1080: ...0 3 TCU ACTYON 2006 03 0000 00 0000 00 TCU 1 TCU ...

Page 1081: ...0 4 ACTYON 2006 03 0000 00 TCU ...

Page 1082: ...0 5 TCU ACTYON 2006 03 0000 00 ...

Page 1083: ...0 6 ACTYON 2006 03 0000 00 TCU ...

Page 1084: ...0 7 TCU ACTYON 2006 03 0000 00 ...

Page 1085: ...0 8 ACTYON 2006 03 0000 00 TCU ...

Page 1086: ...0 9 TCU ACTYON 2006 03 0000 00 ...

Page 1087: ...0 10 ACTYON 2006 03 0000 00 TCU ...

Page 1088: ...0 11 TCU ACTYON 2006 03 0000 00 ...

Page 1089: ...0 12 ACTYON 2006 03 0000 00 TCU ...

Page 1090: ...0 13 TCU ACTYON 2006 03 0000 00 ...

Page 1091: ...0 14 ACTYON 2006 03 0000 00 TCU ...

Page 1092: ...0 15 TCU ACTYON 2006 03 0000 00 ...

Page 1093: ...0 16 ACTYON 2006 03 0000 00 TCU ...

Page 1094: ...0 17 TCU ACTYON 2006 03 0000 00 ...

Page 1095: ...0 18 ACTYON 2006 03 0000 00 TCU ...

Page 1096: ...0 19 TCU ACTYON 2006 03 0000 00 ...

Page 1097: ......

Page 1098: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 1099: ......

Page 1100: ...0 3 TGS LEVER ACTYON 2006 03 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 1101: ...0 4 ACTYON 2006 03 0000 00 TGS LEVER ...

Page 1102: ...0 5 TGS LEVER ACTYON 2006 03 0000 00 ...

Page 1103: ...0 6 ACTYON 2006 03 0000 00 TGS LEVER ...

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