SSANGYONG Actyon 2008.01 Page 64 Manual Download

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02-5

ENGINE ASSEMBLY

ACTYON 2008.01

1212-01

Oil separator

Injector cover

(10 ± 1.0 Nm → 180 + 20°)

Oil pipe

Fuel pressure sensor

Water outlet port

EGR valve

Oil filler

Booster pressure sensor

Common rail

Vacuum pump

Glow plug

Cylinder head cover

VGT Turbo charger

Top View

(40 ± 4.0 Nm)

(25 ± 2.5 Nm)

(10 ± 1.0 Nm)

(15 ± 3 Nm)

Summary of Contents for Actyon 2008.01

Page 1: ... 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 12 13 14 15 17 ...

Page 2: ...0 2 ACTYON 2008 01 0000 00 GENERAL ...

Page 3: ...0 3 GENERAL ACTYON 2008 01 0000 00 4110 01 GENERAL 1 DIMENSIONS ...

Page 4: ...0 4 ACTYON 2008 01 0000 00 GENERAL 2 SPECIFICATIONS ...

Page 5: ...0 5 GENERAL ACTYON 2008 01 0000 00 ...

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

Page 7: ...ent 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 Check the engine oil level and leak every 3 000 k...

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: ...d their related parts If necessary correct clean replenish adjust or replace Replace or change In order to secure engine long life and effective break in first oil factory filled would be recommended to drain with in 10 000 km I R 1 If vehicle is operated under severe condition short distance driving extensive idling or driving in dusty condition shorten the service interval 2 If vehicle is operat...

Page 10: ...ehicle is operated under any of the following conditions In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain or When doing frequent trailer towing or Uses such as found in taxi police or delivery service 5 Inspect manual transmission fluid every 15 000 km Inspect the leak of fluid at any time occasionally then change every 60 ...

Page 11: ...ff road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for looseness 7 If necessary rotate and balance wheels 8 Inspect propeller shaft grease every 5 000 km or 3 months if the vehicle is mainly driven under severe condition In off road or dusty road or In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In h...

Page 12: ...AL 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 13: ...0 13 GENERAL ACTYON 2008 01 0000 00 6 JACK UP POINTS ...

Page 14: ...0 14 ACTYON 2008 01 0000 00 GENERAL 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 1 Functions of Terminal It is installed under the instrument panel and consists of 16 pins ...

Page 15: ...0 15 GENERAL ACTYON 2008 01 0000 00 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 16: ...0 16 ACTYON 2008 01 0000 00 GENERAL 2 Components Locator ...

Page 17: ...0 17 GENERAL ACTYON 2008 01 0000 00 9 STANDARD BOLTS SPECIFICATIONS ...

Page 18: ...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 19: ...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 20: ......

Page 21: ...01 3 ENGINE GENERAL ACTYON 2008 01 0000 00 0000 00 ENGINE GENERAL 1 ENGINE ASSEMBLY LAYOUT 1 LH SIDE VIEW 2 RH SIDE VIEW ...

Page 22: ...01 4 ACTYON 2008 01 0000 00 ENGINE GENERAL 3 FRONT VIEW 4 FAN BELT ...

Page 23: ... 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 24: ...01 6 ACTYON 2008 01 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 25: ...01 7 ENGINE GENERAL ACTYON 2008 01 0000 00 Knock Sensor 1 EA Water Temperature Sensor Vacuum Modulator Crankshaft Position Sensor Water temp sensor Knock sensor HP Pump ...

Page 26: ...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 27: ...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 28: ...TYON 2008 01 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 29: ...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 30: ...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 31: ...N 2008 01 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 32: ...1 14 ACTYON 2008 01 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 33: ...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 34: ...01 16 ACTYON 2008 01 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 35: ...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 36: ...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 37: ...01 19 ENGINE GENERAL ACTYON 2008 01 0000 00 Engine Oil Filter Cooler Oil cooler Oil filter Oil cooler Oil filter cap Oil pressure switch ...

Page 38: ...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 39: ...01 21 ENGINE GENERAL ACTYON 2008 01 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 40: ...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 41: ... 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 42: ...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 43: ...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 44: ...ue by SCAN 100 after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes 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 current faults and erase the history faults 1...

Page 45: ...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 46: ...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 47: ... 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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...hicle and then support with chassis stand before service work Before service work be sure to disconnect 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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ... 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 59: ...01 41 ENGINE GENERAL ACTYON 2008 01 0000 00 16 STANDARD BOLTS SPECIFICATIONS ...

Page 60: ...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 61: ...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 62: ... ASSEMBLY ACTYON 2008 01 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 63: ...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 64: ...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 65: ... 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 66: ... 01 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 67: ...02 8 ACTYON 2008 01 1212 01 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 68: ...02 9 ENGINE ASSEMBLY ACTYON 2008 01 1212 01 2 Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 69: ...02 10 ACTYON 2008 01 1212 01 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 70: ...02 11 ENGINE ASSEMBLY ACTYON 2008 01 1212 01 ...

Page 71: ...02 12 ACTYON 2008 01 1212 01 ENGINE ASSEMBLY ...

Page 72: ...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 73: ...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 74: ...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 75: ...04 6 ACTYON 2008 01 2313 01 ENGINE INTAKE SYSTEM 2 Layout ...

Page 76: ...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 77: ...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 78: ...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 79: ...04 10 ACTYON 2008 01 2313 01 ENGINE INTAKE SYSTEM 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 80: ... 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 81: ...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 82: ...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 83: ...05 6 ACTYON 2008 01 1913 01 ENGINE EXHAUST SYSTEM 2 Exhaust Gas Flows ...

Page 84: ...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 40 140 C Operating pressure 0 3 0 55 bar Permissible pressure 10 bar Severe Condition 2 OIL PRESSURE SWITCH 1533 01 LUBRICATION SYSTEM ...

Page 85: ...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 86: ...06 5 LUBRICATION SYSTEM ACTYON 2008 01 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 87: ... LUBRICATION SYSTEM Cylinder Head Cylinder Block 2 Lubrication System Layout Main oil gallery φ 16 Hole to cylinder head φ 9 Main bearing hole φ 7 Chain and injection pump φ 7 Return hole φ 14 Chain nozzle φ 1 HP pump bearing φ 6 ...

Page 88: ...YON 2008 01 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 89: ...07 3 COOLING SYSTEM ACTYON 2008 01 2112 01 9210 05 ENGINE COOLING SYSTEM 1 ENGINE COOLING SPECIFICATIONS ...

Page 90: ...07 4 ACTYON 2008 01 2112 01 COOLING SYSTEM Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor 1 COMPONENTS ENGINE COOLING ...

Page 91: ...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 92: ...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 93: ...08 3 ENGINE ELECTRIC DEVICES ACTYON 2008 01 1451 01 1461 01 ENGINE ELECTRICAL SYSTEM 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 94: ...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 95: ...INE ELECTRIC DEVICES ACTYON 2008 01 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 96: ...08 6 ACTYON 2008 01 1451 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM 1 Preheating ...

Page 97: ...08 7 ENGINE ELECTRIC DEVICES ACTYON 2008 01 1451 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR 1 Starting Charging ...

Page 98: ...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 99: ...09 4 ACTYON 2008 01 1491 01 ENGINE CONTROL SYSTEM 2 TOP VIEW Fuel Pressure Sensor Booster Pressure Sensor Injectors 4 EA Glow Plugs 4 EA ...

Page 100: ...09 5 ENGINE CONTROL SYSTEM ACTYON 2008 01 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock Sensors 1 EA Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 101: ...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 102: ... 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 103: ...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 104: ...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 105: ... 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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...SPECIAL SERVICE TOOLS 0000 00 SPECIAL SERVICE TOOLS GENERAL 1 ENGINE ASSEMBLY 2 ENGINE HOUSING ASSEMBLY SPECIAL TOOLS ANDEQUIPMENT 3 ENGINE INTAKE 3 5 7 ...

Page 117: ...10 2 ACTYON 2008 01 0000 00 SPECIAL SERVICE TOOLS ...

Page 118: ...r Washer Puller Y99220022B Valve Remover Installer Y99220082B Pulley Lock Wrench Y99220052B Engine Lock 602 589 00 40 00 Injector Puller Y99220072B Glow Plug Wrench Y99220132B Fuel Pipe Wrench Sealing Caps 665 995 5844 0000 00 SPECIAL SERVICE TOOLS 1 ENGINE ASSEMBLY ...

Page 119: ...10 4 ACTYON 2008 01 0000 00 SPECIAL SERVICE TOOLS Glow Plug Socket Removal Installation Device for HP Pump Removal Installation Socket for High Pressure Pipe Head Bolt Wrench ...

Page 120: ... Name and Part Number Application Y99220092B Compression pressure measuring adapter and gauge Y99220082B Supporting bar and lever Y99220162B Guide pin extractor Y99220112B Intake manifold guide pin 2 ENGINE HOUSING ASSEMBLY SPECIAL TOOLS AND EQUIPMENT ...

Page 121: ...10 6 ACTYON 2008 01 0000 00 SPECIAL SERVICE TOOLS Name and Part Number Application Y99220152B HLA remover Y99220142B Stem seal installer ...

Page 122: ...10 7 SPECIAL SERVICE TOOLS ACTYON 2008 01 0000 00 3 ENGINE INTAKE Name and Part Number Application Y99220112B Intake manifold guide pin Installation of intake manifold ...

Page 123: ......

Page 124: ...eering wheel and when this switch is operating ECO 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 usin...

Page 125: ...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 126: ...11 5 CRUISE CONTROL SYSTEM ACTYON 2008 01 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ... COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The electronically controlled advanced 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 D20DT EURO D20DT ...

Page 133: ...01 4 ACTYON 2008 01 1114 00 ENGINE ASSEMBLY 1 Engine Assembly Structure Front View Top View Touch idler equipped for A T ...

Page 134: ...01 5 ENGINE ASSEMBLY ACTYON 2008 01 1114 00 Right Side View Left Side View ...

Page 135: ...01 6 ACTYON 2008 01 1114 00 ENGINE ASSEMBLY 2 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 136: ...01 7 ENGINE ASSEMBLY ACTYON 2008 01 1114 00 2 Engine Performance Curve 1 Output and Torque General EU4 2 Oil Temperature Pressure and Boost Pressure General EU4 ...

Page 137: ...01 8 ACTYON 2008 01 1114 00 ENGINE ASSEMBLY 3 TIGHTENING TORQUE ...

Page 138: ...01 9 ENGINE ASSEMBLY ACTYON 2008 01 1114 00 ...

Page 139: ...01 10 ACTYON 2008 01 1114 00 ENGINE ASSEMBLY ...

Page 140: ...er head bolt changes of the DI engine D20DT Cylinder head bolt wrench Tightening Torque A Removal order Remove the bolts in the order as shown in the figure Installation order Based on the number in the picture B 10 9 8 7 6 5 4 3 2 1 14 13 12 11 Reverse order of removal W9912 003 0B I D of head bolt head 14 5 mm O D of head bolt wrench 13 3 mm ...

Page 141: ...1114 00 ENGINE ASSEMBLY 4 MAJOR CHANGES IN D20DT EURO IV ENGINE COMPARED TO D20DT 1 Engine Assembly D20DT EURO 4 Engine D20DT Engine Front Side View Top Side View Right Side View Left Side View Touch idler equipped for A T ...

Page 142: ...ed due to the increased capacity D20DT EURO4 Added damping orifice Orifice is added to fuel inlet outlet ports in order to dampen the pulsation in fuel flow caused by multi injections E EGR valve ECU controls the EGR valve directly without any media It provide more precise EGR control by transmitting the electric signal of EGR valve operating position Injector Fuel pipe Fuel high pressure pipe Com...

Page 143: ...air to intake manifold is blocked by closed flap when the engine is switched off To enhance EGR function coolant EGR cooler is adopted to reduce the temperature of exhaust gas into the intake manifold Reason of changes To satisfy the emission regulation E EGR valve and EGR cooler are adopted And the layout also has a great difference from D27DT HFM 6 0 HFM 5 0 Throttle body EGR cooler EGR center p...

Page 144: ...he mounting location of booster pressure sensor is changed For D20DT EURO4 engine Additional connecting port for EGR cooler hose For D20DT EURO4 engine Additional port for coolant of EGR cooler Coolant outlet port Water pump Intake manifold PCV oil separator PCV valve Cylinder head cover oil gas Oil To oil gage pipe Oil separator Blow by gas To air duct hose PCV valve Oil separator Oil To oil gage...

Page 145: ...gits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D20DT engine the injector MDP minimum current for the solenoid in the injector to lift the nozzle is leaned only when the engine is running However for the D20DT EURO 4 engine it is learned when the vehicle is in motion and the engine is at idle speed 2 Common Rail The orifice is added to the conn...

Page 146: ...l rail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail ...

Page 147: ......

Page 148: ...ase in I D Common Rail Orifice for Preventing Fuel Pulsation Added 1 COMPONENTS OF FUEL SYSTEM Injector 7 way Injection and C3I Coding C3I Fuel nozzle holes 7 Orifice Orifice for HP pump fuel outlet Fuel pipe Common rail High pressure fuel pipe Fuel rail pressure sensor ...

Page 149: ...iming Pump Fuel filter Priming pump Connector Fuel from HP pump Fuel filter HP pump Fuel tank Fuel tank Fuel return port Low pressure fuel supply port Venturi Fuel return port Fuel temperature sensor IMV connector High pressure fuel supply port orifice included IMV valve ...

Page 150: ...02 8 ACTYON 2008 01 1881 00 ENGINE FUEL SYSTEM 2 FUEL FLOW OF D20DT EURO 4 ENGINE ...

Page 151: ...equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased ...

Page 152: ...008 01 2321 01 ENGINE INTAKE SYSTEM 2 INTAKE SYSTEM LAYOUT Uncompressed air Compressed air Ambient air Air cleaner VGT Turbo Chargera HFM Sensor ver 6 0 Air coeaner Turbo charger Temperature sensor Pretension graph ...

Page 153: ...ld Intercooler Turbo charger Intake manifold Throttle body Coolant port Compress ed air EGR gas To corresponding cylinders Booster Pressure Sensor Ground Supply power Output voltage Throttle body Normal flap open Engine stopped flap closed Intake duct Intake duct ...

Page 154: ...lly and sends the valve location signal to ECU vacuum modulator control has been deleted EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe EGR cooler E EGR valve To EGR cooler Exhaust manifold E EGR valve Coolant Intake manifold Intake manifold EGR gas From EGR cooler Turbocharger intercooler Intake compressed air Exhaust manifold EGR pipe EGR ...

Page 155: ...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 PCV valve Oil separator PCV valve Oil separator Blow by gas To air duct ho...

Page 156: ... overlapped in normal driving mode These are the cause of oil and carbon accumulated in the intake pipe When the EGR system is operated the particulate material in the exhaust gas is drawn into the intake pipe and the oil not filtered in the PCV oil separator is also drawn into the intake pipe However unless the particulate material or oil are accumulated excessively in the pipe they do not affect...

Page 157: ...ENGINE COOLING SYSTEM 2112 00 1520 00 ENGINE COOLING SYSTEM COOLING SYSTEM 1 COMPARISON IN COOLING SYSTEM FOR EACH ENGINE WATER PUMP 1 OVERVIEW 3 5 ...

Page 158: ...06 2 ACTYON 2008 01 0000 00 ENGINE COOLING SYSTEM ...

Page 159: ...YSTEM 1 COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D20DT EURO4 engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block 1 Cooling System for Engine ...

Page 160: ...ft and a belt pulley The impeller is supported by a completely sealed bearing The water pump is serviced as an assembly and therefore cannot be disassembled The capacity of water pump has been increased due to the EGR cooler increased engine power and additional coolant port in the cylinder block For D20DT EURO4 engine For D20DT engine Port to EGR cooler ...

Page 161: ...06 5 ENGINE COOLING SYSTEM ACTYON 2008 01 0000 00 1 Structure of Water Pump for D20DT Engine ...

Page 162: ......

Page 163: ...CU pin for D20DT EURO4 engine and D20DT engine are not same For more details refer to the respective section E EGR Electric Exhaust Gas Recirculation Valve It is electrically controlled by the ECU for precise control Old version was controlled by the vacuum modulator Throttle Body It is electrically controlled by ECU as E EGR valve AQGS Advanced Quick Glow System Unit The glow control relay K line...

Page 164: ...07 4 ACTYON 2008 01 1491 01 ENGINE ELECTRICAL SYSTEM 2 D20DT EURO4 ENGINE S ECU CIRCUIT ...

Page 165: ...SPECIAL SERVICE TOOLS 0000 00 SPECIAL SERVICE TOOLS GENERAL 1 LOCATION OF ENGINE AND MAJOR SPECIAL SERVICE TOOLS 3 ...

Page 166: ...08 2 ACTYON 2008 01 0000 00 SPECIAL SERVICE TOOLS ...

Page 167: ...ps Fuel line Removal Installation Device for HP Pump Removal InstallationSocketfor HighPressurePipe Head Bolt Wrench Injector Puller Glow Plug Socket Injector copper washer Puller 0000 00 SPECIAL SERVICE TOOLS 1 LOCATION OF ENGINE AND MAJOR SPECIAL SERVICE TOOLS ...

Page 168: ......

Page 169: ...eering wheel and when this switch is operating ECO 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 usin...

Page 170: ...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 171: ...09 5 CRUISE CONTROL SYSTEM ACTYON 2008 01 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 172: ...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 173: ...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 174: ...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 175: ...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 176: ...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 177: ... during assembly to protect and lubricate the surfaces on initial operation Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated Whenever valve train components are removed for service they should be kept in order They should be installed in the same locations and with the sa...

Page 178: ...posed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Any time the air cleaner is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the ...

Page 179: ...01 5 ENGINE ASSEMBLY ACTYON 2008 01 1113 01 2 G23D ENGINE ASSEMBLY Front View Rear View ...

Page 180: ...01 6 ACTYON 2008 01 1113 01 ENGINE ASSEMBLY LH Side View RH Side View ...

Page 181: ...01 7 ENGINE ASSEMBLY ACTYON 2008 01 1113 01 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 182: ...ting Rod 6 Fuel Distributor 17 Crankshaft 7 Injector 18 Engine Mounting Bracket 8 Exhaust Camshaft 19 Starter 9 Intake Camshaft 20 Crankcase 10 Valve Tappet 21 Oil Pump Sprocket 11 Intake Valve 22 Oil Pan NO FUNCTION NO FUNCTION 23 Camshaft Adjuster 29 Oil Pump Drive Chain 24 Oil Filler Cap 30 Oil Strainer 25 Engine Hanger Bracket 31 Oil Pump 26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flyw...

Page 183: ...location of the leak by the drippings on the paper Visually check around the suspected component Check around all the gasket mating surfaces for leaks A mirror is useful for finding leaks in areas that are hard to reach If the leak still cannot be found it may be necessary to clean the suspected area with a degreaser steam or spray solvent Clean the area well Dry the area Operate the vehicle for s...

Page 184: ...source the cause of the leak must be determined in order for it to be repaired properly If a gasket is replaced but the sealing flange is bent the new gasket will not repair the leak The bent flange must be repaired also Before attempting to repair a leak check for the following conditions and correct them as they may cause a leak Repairing the Leak Gaskets The fluid level pressure is too high The...

Page 185: ... compression pressure tester A9912 0012B 001 589 76 21 00 and install it into the spark plug hole Crank the engine approx eight revolutions by using the start motor Compare the measurements of compression pressure tester A9912 0012B 001 589 76 21 00 with the specifications Measure the compression pressure of the other cylinders in the same way If measured value is not within the specifications per...

Page 186: ...ssure LeakageTest Permissible Pressure Leakage At Whole Engine Max 25 At Valve and Cylinder Head Gasket Max 10 At Piston and Piston Ring Max 20 OT TDC 1 4 UT BDC 180 2 3 Cylinder Number Cylinder Number Cylinder Pressure Leakage Tester Bosch EFAW210A Sun CLT 228 ...

Page 187: ... pressure line and adjust the scale of tester Install the connecting hose to spark plug hole Position the piston of No 1 cylinder at TDC by rotating the crankshaft Connect the connecting hose to tester and measure the leakage volume after blowing up 5 bar of compressed air Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable Perform the...

Page 188: ...01 14 ACTYON 2008 01 1113 01 ENGINE ASSEMBLY 5 GENERAL DIAGNOSIS ...

Page 189: ...01 15 ENGINE ASSEMBLY ACTYON 2008 01 1113 01 General Diagnosis Cont d ...

Page 190: ...01 16 ACTYON 2008 01 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 191: ...01 17 ENGINE ASSEMBLY ACTYON 2008 01 1113 01 General Diagnosis Cont d ...

Page 192: ...01 18 ACTYON 2008 01 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 193: ...01 19 ENGINE ASSEMBLY ACTYON 2008 01 1113 01 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 194: ...01 20 ACTYON 2008 01 1113 01 ENGINE ASSEMBLY 2 Fastener Tightening Specifications ...

Page 195: ...01 21 ENGINE ASSEMBLY ACTYON 2008 01 1113 01 Fastener Tightening Specifications Cont d ...

Page 196: ...01 22 ACTYON 2008 01 1113 01 ENGINE ASSEMBLY 2 Performance Curve ...

Page 197: ......

Page 198: ...02 3 ENGINE INTAKE SYSTEM ACTYON 2008 01 1713 08 0000 00 ENGINE INTAKE SYSTEM 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 199: ...03 3 ENGINE EXHAUST SYSTEM ACTYON 2008 01 2420 01 2420 01 ENGINE EXHAUST SYSTEM 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 200: ...talytic converter Use of anything other than unleaded fuel will damage the catalyst in the catalytic converter 1 2 Catalytic Converter Structure The Catalytic converter of monolith type consists of 2 walled metal bodies which is made of Cordierite The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to Ceramic Monolith Washer coat operates ...

Page 201: ... normal range of temperature CO purification rate becomes the best near the temperature of 450 C and NOx does so near the temperature of 400 to 500 C Purification of Catalytic Converter Adhesion of soluble organic fraction SOF below 180 C Purification of soluble organic fraction SOF over 180 C Chemical reaction formula SOF HC O2 CO2 H2O 2CO O2 2CO2 2C2H6 7O2 4CO2 6H20 By catalytic action of two pr...

Page 202: ...r factor are high EGR valve can decrease NOx 30 to 35 decrease by making temperature of combustion chamber fall by means of exhaust gas re circulation EGR valve is installed on the diesel engine of Musso Korando Istana and Rexton And micro switch is installed together to control EGR valve The setting method of micro switch is identical with the existing one ...

Page 203: ...04 3 ENGINE COOLING SYSTEM ACTYON 2008 01 2112 01 2110 01 ENGINE COOLING SYSTEM 1 GENERAL SPECIFICATIONS ...

Page 204: ...04 4 ACTYON 2008 01 2112 01 ENGINE COOLING SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 205: ...2 01 1 COMPONENT LOCATOR 1 Reserver Tank 2 Deaeration Tube 3 Inlet Hose 4 Outlet Hose 5 3 way Hose 6 Clamp 7 Clamp 8 Bolt M6 2 piece 9 Radiator 10 Lower Radiator Insulator 11 Plate 12 Clip 13 Upper Radiator Insulator 14 Bracket 15 PWM Electric Fan ...

Page 206: ...he correct coolant level The cooling system for this vehicle has no radiator cap or filler neck The coolant is added to the cooling system through the coolant reservoir 2 Radiator This vehicle has a lightweight tube and fin aluminum radiator Plastic tanks are mounted on the upper and the lower sides of the radiator core On vehicles equipped with automatic transaxles the transaxle fluid cooler line...

Page 207: ...osing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits The wax pellet in the thermostat is hermetically sealed in a metal case The wax element of the thermostat expands when it is heated and contracts when it is cooled As the vehicle is driven and the engine warms the engine coolant temperature increases When...

Page 208: ...d cooling fan relay and a cooling fan motor relay The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 95 C 203 F and at high speed when the coolant temperature reaches 105 C 221 F The ECM will change the cooling fans from high peed to low speed at 100 C 212 F and will turn the cooling fans off at 90 C 194 F A C On The ECM will turn the cooling fans on at low spe...

Page 209: ...MODULATION ELECTRIC FAN OPERATION 1 Function The PWM Pulse Width Modulation high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise 2 Mounting Location PWM Fan shroud Electric fan PWM unit ...

Page 210: ...h Modulation Unit It controls the time of the output voltage to control the fan motor speed independently Internal functions Motor power shutting off function when overcurrent is applied Adverse voltage prevention function Detection function for the motor lock Temperature detecting function The electric fan operates at FULL speed to cool down the PWM unit when the interior temperature of PWM unit ...

Page 211: ...m for 4 seconds after engine starting abrupt acceleration and A C refrigerant pressure sensor detecting the followings A C compressor is turned off when the refrigerant pressure is below 2 0 kg cm2 and then is turned on when the refrigerant pressure is over 2 4 kg cm2 A C compressor is turned off when the refrigerant pressure is over 30 kg cm2 and then is turned on when the refrigerant pressure is...

Page 212: ...05 3 ENGINE ELECTRICAL SYSTEM ACTYON 2008 01 1452 01 0000 00 ENGINE ELECTRIC DEVICES 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 213: ...05 4 ACTYON 2008 01 1452 01 ENGINE ELECTRICAL SYSTEM 2 Ignition System Cont d ...

Page 214: ... More power available in a lighter smaller case The battery has three major functions in the electrical system First the battery provides a source of energy for cranking the engine Second the battery acts as a voltage stabilizer for the electrical system Finally the battery can for a limited time provide energy when the electrical demand exceeds the output of the generator 2 Ratings A battery has ...

Page 215: ...keep the battery cable terminals clean and tight or a loose battery hold down clamp Mechanical problems in the electrical system such as shorted or pinched wires 3 Charging Time Required The time required to charge a battery will vary depending upon the following factors Size of Battery A Completely discharged large heavy duty battery required more than twice the recharging time as a completely di...

Page 216: ...ery may not have enough voltage to activate this circuitry even though the leads are connected properly making it appear that the battery will not accept charging current Therefore follow the specific charger manufacturer apos s instruction for by passing or overriding the circuitry so that the charger will turn on and charge a low voltage battery Continue to charge the battery until the charge cu...

Page 217: ... Do not attach the cable directly to the neg ative terminal of the discharged battery Doing so could cause sparks and possible battery explosion Clamp one end of the second cable to the negative terminal of the booster battery Make the final connection to a solid engine ground such as the engine lift bracket at least 450 millimeters 18 inches from the discharged battery Start the engine of the veh...

Page 218: ...cal loads the on time may be 90 percent and the off time 10 percent 7 Charging System Generators use a new type of regulator that incorporates a diode trio A Delta stator a rectifier bridge and a rotor with slip rings and brushes are electrically similar to earlier generators A conventional pulley and fan are used There is no test hole 8 Starter Wound field starter motors have pole pieces arranged...

Page 219: ... all the related wiring Diagnostic tables will aid in troubleshooting system faults When a fault is traced to a particular component refer to that component section of the service manual The starting system circuit consists of the battery the starter motor the ignition switch and all the related electrical wiring All of these components are connected electrically ...

Page 220: ...ENGINE SPECIAL SERVICE TOOLS 0000 00 ENGINE SPECIAL SERVICE TOOLS GENERAL 1 SPECIAL SERVICE TOOLS AND EQUIPMENT FOR ENGINE ASSEMBLY 2 SPECIAL SERVICE TOOLS AND EQUIPMENT FOR ENGINE COOLING SYSTEM 3 6 ...

Page 221: ...06 2 ACTYON 2008 01 0000 00 ENGINE SPECIAL SERVICE TOOLS ...

Page 222: ...r 0000 00 ENGINE SPECIAL SERVICE TOOLS 1 ENGINE ASSEMBLY A9913 0010B 000 589 58 43 00 Chain Assembly A9917 0101B 111 589 01 59 00 Supporting Bar W9911 0010B 102 589 00 15 00 Drift A9917 0111B 111 589 18 61 00 Lever Pusher A9911 0050B 102 589 12 15 00 Drift A9917 0121B 111 589 25 63 00 Thrust Piece ...

Page 223: ...ilter Remover A9913 0061B 116 589 01 34 00 Threaded Pin A9917 0171B 119 589 00 43 00 Drift W9911 0050B 615 589 01 33 00 Crankshaft Sprocket Puller A9911 0060B 601 589 03 14 00 Crankshaft Front Seal Installer A9912 0080B 617 589 00 10 00 Allen Wrench Socket A9910 0150B 602 589 00 40 00 Engine Lock A9911 0012B DW110 090 Connecting Hose ...

Page 224: ...1 0000 00 Name and Part Number Name and Part Number W9911 0020B 601 589 03 43 00 Crankshaft Rear Seal Installer A9917 0012B DW110 120 Holding Pin A9910 0150A 603 589 00 40 00 Fan Clutch Holder A99120012B 001 589 76 21 00 Compression Pressure Tester ...

Page 225: ...VICE TOOLS 2 ENGINE COOLING SYSTEM Name and Part Number Name and Part Number A9910 0060A 111 589 00 40 00 Holder A9910 0070A 111 589 02 01 00 Open End Wrench A9921 0012A 124 589 15 21 00 Leakage Tester A9910 0150A 603 589 00 40 00 Fan Clutch Holder ...

Page 226: ...eering wheel and when this switch is operating ECO 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 usin...

Page 227: ...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 228: ...07 5 CRUISE CONTROL SYSTEM ACTYON 2008 01 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 229: ...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 230: ...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 231: ...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 232: ...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 233: ...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 234: ...ECTRIC SYSTEM GENERAL 1 LOCATIONS OF INTERIOR UNITS AND SENSORS 2 LOCATION AND COMPARTMENT OF INTERIOR SWITCHES 3 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT 4 ELECTRIC COMPONENTS AND LAYOUT 5 DIAGNOSTIC CONNECTOR 2 4 6 8 10 ...

Page 235: ...01 2 ACTYON 2008 01 0000 00 ELECTRIC SYSTEM 0000 00 ELECTRIC GENERAL 1 LOCATIONS OF INTERIOR UNITS AND SENSORS ...

Page 236: ...01 3 ELECTRIC SYSTEM ACTYON 2008 01 0000 00 ...

Page 237: ...01 4 ACTYON 2008 01 0000 00 ELECTRIC SYSTEM 2 LOCATION AND COMPARTMENT OF INTERIOR SWITCHES ...

Page 238: ...01 5 ELECTRIC SYSTEM ACTYON 2008 01 0000 00 ...

Page 239: ...01 6 ACTYON 2008 01 0000 00 ELECTRIC SYSTEM 3 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT ...

Page 240: ...01 7 ELECTRIC SYSTEM ACTYON 2008 01 0000 00 ...

Page 241: ...01 8 ACTYON 2008 01 0000 00 ELECTRIC SYSTEM 4 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 242: ...01 9 ELECTRIC SYSTEM ACTYON 2008 01 0000 00 2 Components Locator ...

Page 243: ...0 ELECTRIC SYSTEM 5 DIAGNOSTIC CONNECTOR 1 Pin Arrangement of Diagnostic Connector It is installed under the instrument panel and consists of 16 pins The REKES key coding should be performed with Scan 100 2 Functions of Terminal ...

Page 244: ...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 245: ...0 4 ACTYON 2008 01 8410 02 FUSES AND REALYS 2 Interior Fuses and Relays Fuse and Relay Box LH Fuse and Relay Box RH ...

Page 246: ...0 5 FUSES AND REALYS ACTYON 2008 01 8410 02 2 DESIGNATION AND CAPACITY OF FUSES AND RELAY 1 Fuses and Relays in Engine ...

Page 247: ...0 6 ACTYON 2008 01 8410 02 FUSES AND REALYS 2 Designation and Capacity 1 Driver Side ...

Page 248: ...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 249: ...0 8 ACTYON 2008 01 8410 02 FUSES AND REALYS 3 POWER DISTRIBUTION For details refer to the electric circuit diagram ...

Page 250: ...0 9 FUSES AND REALYS ACTYON 2008 01 8410 02 For details refer to the electric circuit diagram ...

Page 251: ...0 10 ACTYON 2008 01 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 252: ...0 11 FUSES AND REALYS ACTYON 2008 01 8410 02 2 IP Interior Fuse Passenger Side For details refer to the electric circuit diagram ...

Page 253: ...door ajar warning light in the instrument cluster does not come on even though the deck tailgate is opened Rear Wiper and Washer System Eliminated Tailgate Open Switch Eliminated Opening Closing of the deck tailgate is not related to the operation condition of the theft deterrent mode The deck tailgate can be controlled as lock unlock status depending on the operation of central locking system by ...

Page 254: ...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 255: ...02 5 STICS ACTYON 2008 01 8710 01 Rated Load ...

Page 256: ...02 6 ACTYON 2008 01 8710 01 STICS Input Signals ...

Page 257: ...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 258: ...KES STICS Super Time Integrated Control System is almost the same as that of ACTYON in terms of its function and role Due to the removal of tailgate opening switch and rear wiper and washer system the circuit layout is slightly changed compared to ACTYON Door Lock Relay RK STICS REKES key ...

Page 259: ... 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 260: ...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 261: ...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 262: ...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 263: ...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 264: ...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 265: ...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 266: ...02 16 ACTYON 2008 01 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 267: ...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 268: ...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 269: ...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 270: ...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 271: ...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 272: ...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 273: ... 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 274: ...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 275: ...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 276: ...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 277: ...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 278: ...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 279: ...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 280: ...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 281: ...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 282: ...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 283: ...while the vehicle speed is below 10 km h The warning light goes off when turning off the parking brake switch under step 2 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 The warning light goes off and the chime buzzer stops when ...

Page 284: ... 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 285: ...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 286: ...the door after step 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 ...

Page 287: ...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 288: ...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 289: ...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 290: ...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 291: ...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 292: ...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 293: ...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 294: ...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 295: ...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 296: ...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 inserted or the door lock switch is unlocked it cancels the armed mode and activates the normal mode When the door is opened or the ignition key is not inserted into ignition switch within...

Page 297: ... and hazard warning flasher output is ON for 27 seconds at the interval of 1 second Warning cancellation requirements 1 Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC during warning operation 2 Cancels warning after 27 seconds remaining time while the ignition key is turned to ON position 3 If the ignition switch is turned to ON position when the warning is activ...

Page 298: ...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 299: ...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 300: ...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 301: ...02 51 STICS ACTYON 2008 01 8710 01 3 CIRCUIT DIAGRAM The circuit diagram below shows the input and output of STICS 1 STICS Input Singnals and Others ...

Page 302: ...02 52 ACTYON 2008 01 8710 01 STICS 2 STICS Output Signals and Others ...

Page 303: ...53 STICS ACTYON 2008 01 8710 01 3 Circuit Diagram of Wiper Rear wiper and washer system is not applied the circuit related to rear wiper and washer is removed from the STICS circuit regarding wiper control ...

Page 304: ...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 305: ... 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 306: ...o the 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 307: ...02 57 STICS ACTYON 2008 01 8710 01 7 Wiring Circuit of STICS Related to Tail Lamp Auto Cut Battery Saver ...

Page 308: ...n pressing 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 309: ...02 59 STICS ACTYON 2008 01 8710 01 9 Circuit Diagram of STICS Related to Remote Controller and Door Lock Unlock ...

Page 310: ......

Page 311: ...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 312: ...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 313: ......

Page 314: ...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 315: ...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 316: ...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 317: ...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 318: ...03 10 ACTYON 2008 01 7010 06 IMMO 5 CIRCUIT DIAGRAM ...

Page 319: ...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 320: ...ndicator 21 ABS warning light 7 4WD HIGH indicator 22 Engine oil pressure warning light 8 4WD CHECK warning light 23 Glow indicator 9 Water separator warning light 24 Low fuel level warning light 10 Seat belt reminder 25 Engine hood open warning light 11 Speedometer 26 Over temperature warning light 12 ODOmeter Trip odometer 27 Power mode indicator 13 Coolant temperature gauge 28 Winter mode indic...

Page 321: ...05 4 ACTYON 2008 01 8010 01 CLUSTER 2 WARNING INDICATOR PANEL ...

Page 322: ...05 5 CLUSTER ACTYON 2008 01 8010 01 ...

Page 323: ...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 324: ...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 325: ...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 326: ...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 327: ...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 328: ...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 329: ...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 330: ...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 331: ...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 332: ...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 333: ...05 16 ACTYON 2008 01 8010 01 CLUSTER 4 CIRCUIT DIAGRAM ...

Page 334: ...05 17 CLUSTER ACTYON 2008 01 8010 01 ...

Page 335: ...06 3 LAMP ACTYON 2008 01 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 336: ...06 4 ACTYON 2008 01 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 337: ...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 338: ...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 339: ...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 340: ... 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 341: ...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 342: ...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 3 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 343: ...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 344: ...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 345: ...08 6 ACTYON 2008 01 7810 01 WIPER 2 SYSTEM LAYOUT OF WIPER AND WASHER WITH RAIN SENSOR ...

Page 346: ...08 7 WIPER ACTYON 2008 01 7810 01 ...

Page 347: ...08 8 ACTYON 2008 01 7810 01 WIPER 3 WIPER WASHER RELATED FUNCTION AND SPECIFICATION 1 Wiper and Washer Fluid Switch Operation ...

Page 348: ...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 349: ...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 350: ...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 351: ...08 12 ACTYON 2008 01 7810 01 WIPER 4 WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM ...

Page 352: ...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 353: ...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 354: ...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 355: ...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 356: ...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 357: ...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 358: ... 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 359: ...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 360: ...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 361: ... 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 362: ...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 20 at 110 5 cm Min 100 at 50 5 cm Vertical Min 20 at 110 5 ...

Page 363: ...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 364: ...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 365: ...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 366: ...10 7 PAS ACTYON 2008 01 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 367: ...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 368: ...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 369: ...10 10 ACTYON 2008 01 8790 03 PAS 4 CIRCUIT DIAGRAM ...

Page 370: ...0 3 AUDIO SYSTEM ACTYON 2008 01 8610 26 8930 01 AUDIO SYSTEM 1 AUDIO SYSTEM OVERVIEW Audio System 6 Speakers ...

Page 371: ...0 4 ACTYON 2008 01 8610 26 AUDIO SYSTEM 2 CIRCUIT DIAGRAM OF AUDIO SYSTEM ...

Page 372: ...02 3 ION 4 SPEED ACTYON 2008 01 3410 01 3640 01 ION 4 SPEED 1 SPECIFICATIONS ...

Page 373: ...02 4 ACTYON 2008 01 3410 01 ION 4 SPEED 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 374: ...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 375: ...02 6 ACTYON 2008 01 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 376: ...02 7 ION 4 SPEED ACTYON 2008 01 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 377: ...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 378: ...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 379: ... 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 380: ...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 381: ...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 382: ...02 13 ION 4 SPEED ACTYON 2008 01 3410 01 ...

Page 383: ...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 384: ... 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 385: ...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 386: ...02 17 ION 4 SPEED ACTYON 2008 01 3410 01 Solenoid Operation during Gearshifts ...

Page 387: ...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 388: ...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 389: ...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 390: ...02 21 ION 4 SPEED ACTYON 2008 01 3410 01 1 Hydraulic Control Circuit ...

Page 391: ... 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 392: ...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 393: ...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 394: ...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 395: ...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 396: ...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 397: ...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 398: ...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 399: ...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 400: ...02 31 ION 4 SPEED ACTYON 2008 01 3410 01 ...

Page 401: ...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 402: ...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 403: ...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 404: ...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 405: ...02 36 ACTYON 2008 01 3410 01 ION 4 SPEED 1 Park and Neutral ...

Page 406: ... 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 407: ...02 38 ACTYON 2008 01 3410 01 ION 4 SPEED 2 Reverse ...

Page 408: ... 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 409: ...02 40 ACTYON 2008 01 3410 01 ION 4 SPEED 3 Manual 1 ...

Page 410: ... 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 411: ...02 42 ACTYON 2008 01 3410 01 ION 4 SPEED 4 Drive 1 ...

Page 412: ...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 413: ...02 44 ACTYON 2008 01 3410 01 ION 4 SPEED 5 Drive 2 and Manual 2 ...

Page 414: ...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 415: ...02 46 ACTYON 2008 01 3410 01 ION 4 SPEED 6 Drive 3 and Manual 3 ...

Page 416: ... 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 417: ...02 48 ACTYON 2008 01 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 418: ...02 49 ION 4 SPEED ACTYON 2008 01 3410 01 7 Drive 3 Lock Up and Manual 3 Lock Up ...

Page 419: ...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 420: ...02 51 ION 4 SPEED ACTYON 2008 01 3410 01 8 Drive 4 Overdrive ...

Page 421: ...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 422: ...02 53 ION 4 SPEED ACTYON 2008 01 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 423: ...02 54 ACTYON 2008 01 3410 01 ION 4 SPEED 9 Drive 4 Lock Up ...

Page 424: ... 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 425: ...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 426: ...03 4 ACTYON 2008 01 3170 01 M T 2 SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION 1 Specifications ...

Page 427: ...03 5 M T ACTYON 2008 01 3170 01 2 Tightening Torque ...

Page 428: ...03 6 ACTYON 2008 01 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 429: ...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 430: ...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 431: ......

Page 432: ...04 3 CLUTCH ACTYON 2008 01 3010 01 1 CLUTCH SPECIFICATIONS 2 TIGHTENING TORQUE 3020 01 CLUTCH ...

Page 433: ...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 434: ...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 435: ...04 6 ACTYON 2008 01 3010 01 CLUTCH Components of Clutch Assembly Concentric Slave Cylinder Clutch Assembly 3 Functions Adapter Pipe Assembly ...

Page 436: ...04 7 CLUTCH ACTYON 2008 01 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 437: ...05 3 AXLE ACTYON 2008 01 4120 01 4120 01 AXLE 1 SPECIFICATIONS OF AXLE 1 Front View 2 Rear View 3 Specifications ...

Page 438: ...2008 01 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 439: ...05 5 AXLE ACTYON 2008 01 4120 01 1 OVERVIEW OF AXLE 1 Front Axle 2 Rear Axle ...

Page 440: ...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 441: ...01 4116 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 442: ...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 443: ...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 444: ... 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 445: ...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 446: ...0 9 TRANSFER CASE ACTYON 2008 01 4116 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 447: ...0 10 ACTYON 2008 01 3240 01 TRANSFER CASE 2 Flow Layout ...

Page 448: ...0 11 TRANSFER CASE ACTYON 2008 01 3240 01 3 2H Mode Rear Wheel Drive 1 Layout ...

Page 449: ...0 12 ACTYON 2008 01 3240 01 TRANSFER CASE 4 4H Mode 4 Wheel Drive High speed 1 Layout ...

Page 450: ...07 3 SUSPENSION ACTYON 2008 01 4411 01 4510 01 SUSPENSION 1 SPECIFICATIONS OF SUSPENSION 2 WHEEL ALIGNMENT ...

Page 451: ...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 452: ...08 4 ACTYON 2008 01 4892 01 ESP 2 SECTIONAL DRAWING 1 Front Disc Brake 2 Rear Disc Brake ...

Page 453: ...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 454: ...08 6 ACTYON 2008 01 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 455: ...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 456: ...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 457: ...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 458: ...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 459: ...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 460: ... 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 461: ...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 462: ...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 463: ...08 15 ESP ACTYON 2008 01 4892 01 The following figure shows the operating range according to driving conditions Operating range Turning Turning ...

Page 464: ...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 465: ...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 466: ... 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 467: ... 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 468: ...equently 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 469: ...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 470: ...rmination slope level when it reaches 5 2 HDC target speed in 2H 4H mode The HDC target speed is the speed that the HDC is not terminated even after the vehicle speed reaches 7 km h but is converted to the stand by mode When the vehicle speed increases again as a result of the increase of the road steepness etc the HDC goes into operation Forward driving 7 km h Reverse driving 7 km h automatic tra...

Page 471: ...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 472: ...s overridden When the internal temperature of HDC system goes over 450 C due to long downhill driving on a steep hill with HDC operated 5 There is no specific temperature sensor in the system but a programmed logic inside the HECU predicts the temperature based on the operating times and conditions of HDC The red HDC warning lamp blinks when the internal temperature goes over 350 C When reaches 45...

Page 473: ...TYON 2008 01 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 474: ...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 475: ...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 476: ...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 477: ... 29 ESP ACTYON 2008 01 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 478: ...08 30 ACTYON 2008 01 4892 01 ESP 7 INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM Input Output of ESP System ...

Page 479: ...08 31 ESP ACTYON 2008 01 4892 01 8 HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM ...

Page 480: ...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 481: ... 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 482: ...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 483: ...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 484: ...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 485: ...08 37 ESP ACTYON 2008 01 4892 01 1 Input and Output Diagram Of ABS System ...

Page 486: ...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 487: ... 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 488: ...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 489: ...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 490: ...09 4 ACTYON 2008 01 4610 06 POWER STEERING 1 SYSTEM LAYOUT ...

Page 491: ...09 5 POWER STEERING ACTYON 2008 01 4610 06 ...

Page 492: ...09 6 ACTYON 2008 01 4610 06 POWER STEERING 2 COMPONENTS ...

Page 493: ...09 7 POWER STEERING ACTYON 2008 01 4610 06 ...

Page 494: ...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 495: ... 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 496: ... 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 497: ...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 498: ...02 7 AIR BAG ACTYON 2008 01 8810 03 ...

Page 499: ... 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 Air bag cover Air bag housing Air bag cushion approx 50 liters Inflator approx 190 Kpa ...

Page 500: ...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 501: ...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 502: ...02 11 AIR BAG ACTYON 2008 01 8810 03 1 Components ...

Page 503: ...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 504: ...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 505: ...CTYON 2008 01 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 506: ...nger 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 Connector Driver s Side Passenger s Side Signal terminal Ground ...

Page 507: ...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 508: ...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 509: ...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 510: ...02 19 AIR BAG ACTYON 2008 01 8810 03 10 Electrical Wiring Diagram ...

Page 511: ... 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 512: ...03 4 ACTYON 2008 01 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 513: ...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 514: ...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 515: ...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 516: ...04 3 SUNROOF ACTYON 2008 01 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 517: ...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 518: ... 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 519: ...04 6 ACTYON 2008 01 7340 01 SUNROOF 6 Circuit Diagram of Sunroof ...

Page 520: ...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 521: ...05 3 BODY INTERIOR ACTYON 2008 01 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 522: ...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 523: ...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 524: ...07 3 BODY REPAIR ACTYON 2008 01 4110 01 4110 01 BODY REPAIR 1 DIMENSIONS ...

Page 525: ...07 4 ACTYON 2008 01 4110 01 BODY REPAIR 2 JACK UP POINTS ...

Page 526: ...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 527: ... 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 528: ...07 7 BODY REPAIR ACTYON 2008 01 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 529: ...07 8 ACTYON 2008 01 4110 01 BODY REPAIR 5 Applied the Asphalt to the Body Panel Improved Anti Vibration ...

Page 530: ......

Page 531: ...NTS This sensor is installed at the front bottom of engine compartment This changes the air source mode by detecting the air pollution and the ambient temperature Manual air conditioner FATCFATC Ambient temperature sensor It changes sun load coming through front windshield into current to input to FATC controller Type Air Conditioner Controller FATC Manual air conditioner ...

Page 532: ... 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 condition to control the air conditioner A sensor that detects coolant temperature and transmits it to engine ECU Condenser Installed i...

Page 533: ...01 4 ACTYON 2008 01 6810 20 AIR CONDITIONER 2 VENTILATION SYSTEM 1 Locations of Vents 2 Air Duct ...

Page 534: ...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 535: ...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 536: ...01 7 AIR CONDITIONER ACTYON 2008 01 6810 20 2 Components ...

Page 537: ...01 8 ACTYON 2008 01 6810 20 AIR CONDITIONER 3 PTC Heater and FFH Heater Layout 1 PTC Heater Assembly Layout 2 FFH Heater Assembly Layout ...

Page 538: ...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 20 C Coolant temperature over 115 C For approx 4 seconds after starting the engine When engine speed is below 650 rpm When engine spee...

Page 539: ......

Page 540: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 541: ......

Page 542: ...0 3 ECU GASOLINE ACTYON 2008 01 0000 00 0000 00 ECU GASOLINE 1 ECU GASOLINE ...

Page 543: ...0 4 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 544: ...0 5 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 545: ...0 6 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 546: ...0 7 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 547: ...0 8 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 548: ...0 9 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 549: ...0 10 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 550: ...0 11 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 551: ...0 12 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 552: ...0 13 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 553: ...0 14 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 554: ...0 15 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 555: ...0 16 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 556: ...0 17 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 557: ...0 18 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 558: ...0 19 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 559: ...0 20 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 560: ...0 21 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 561: ...0 22 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 562: ...0 23 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 563: ...0 24 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 564: ...0 25 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 565: ...0 26 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 566: ...0 27 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 567: ...0 28 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 568: ...0 29 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 569: ...0 30 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 570: ...0 31 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 571: ...0 32 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 572: ...0 33 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 573: ...0 34 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 574: ...0 35 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 575: ...0 36 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 576: ...0 37 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 577: ...0 38 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 578: ...0 39 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 579: ...0 40 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 580: ...0 41 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 581: ...0 42 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 582: ...0 43 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 583: ...0 44 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 584: ...0 45 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 585: ...0 46 ACTYON 2008 01 0000 00 ECU GASOLINE ...

Page 586: ...0 47 ECU GASOLINE ACTYON 2008 01 0000 00 ...

Page 587: ......

Page 588: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 589: ......

Page 590: ...0 3 ECU DIESEL ACTYON 2008 01 0000 00 0000 00 ECU DIESEL 1 ECU DIESEL ...

Page 591: ...0 4 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 592: ...0 5 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 593: ...0 6 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 594: ...0 7 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 595: ...0 8 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 596: ...0 9 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 597: ...0 10 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 598: ...0 11 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 599: ...0 12 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 600: ...0 13 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 601: ...0 14 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 602: ...0 15 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 603: ...0 16 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 604: ...0 17 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 605: ...0 18 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 606: ...0 19 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 607: ...0 20 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 608: ...0 21 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 609: ...0 22 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 610: ...0 23 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 611: ...0 24 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 612: ...0 25 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 613: ...0 26 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 614: ...0 27 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 615: ...0 28 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 616: ...0 29 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 617: ...0 30 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 618: ...0 31 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 619: ...0 32 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 620: ...0 33 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 621: ...0 34 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 622: ...0 35 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 623: ...0 36 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 624: ...0 37 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 625: ...0 38 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 626: ...0 39 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 627: ...0 40 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 628: ...0 41 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 629: ...0 42 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 630: ...0 43 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 631: ...0 44 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 632: ...0 45 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 633: ...0 46 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 634: ...0 47 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 635: ...0 48 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 636: ...0 49 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 637: ...0 50 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 638: ...0 51 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 639: ...0 52 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 640: ...0 53 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 641: ...0 54 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 642: ...0 55 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 643: ...0 56 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 644: ...0 57 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 645: ...0 58 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 646: ...0 59 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 647: ...0 60 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 648: ...0 61 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 649: ...0 62 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 650: ...0 63 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 651: ...0 64 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 652: ...0 65 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 653: ...0 66 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 654: ...0 67 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 655: ...0 68 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 656: ...0 69 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 657: ...0 70 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 658: ...0 71 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 659: ...0 72 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 660: ...0 73 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 661: ...0 74 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 662: ...0 75 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 663: ...0 76 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 664: ...0 77 ECU DIESEL ACTYON 2008 01 0000 00 ...

Page 665: ...0 78 ACTYON 2008 01 0000 00 ECU DIESEL ...

Page 666: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 667: ......

Page 668: ...0 3 BRAKE ACTYON 2008 01 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 669: ...0 4 ACTYON 2008 01 0000 00 BRAKE ...

Page 670: ...0 5 BRAKE ACTYON 2008 01 0000 00 ...

Page 671: ...0 6 ACTYON 2008 01 0000 00 BRAKE ...

Page 672: ...0 7 BRAKE ACTYON 2008 01 0000 00 ...

Page 673: ...0 8 ACTYON 2008 01 0000 00 BRAKE ...

Page 674: ...0 9 BRAKE ACTYON 2008 01 0000 00 ...

Page 675: ...0 10 ACTYON 2008 01 0000 00 BRAKE ...

Page 676: ...0 11 BRAKE ACTYON 2008 01 0000 00 ...

Page 677: ...0 12 ACTYON 2008 01 0000 00 BRAKE ...

Page 678: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 679: ......

Page 680: ...0 3 AIR BAG ACTYON 2008 01 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 681: ...0 4 ACTYON 2008 01 0000 00 AIR BAG ...

Page 682: ...0 5 AIR BAG ACTYON 2008 01 0000 00 ...

Page 683: ...0 6 ACTYON 2008 01 0000 00 AIR BAG ...

Page 684: ...0 7 AIR BAG ACTYON 2008 01 0000 00 ...

Page 685: ...0 8 ACTYON 2008 01 0000 00 AIR BAG ...

Page 686: ...0 9 AIR BAG ACTYON 2008 01 0000 00 ...

Page 687: ...0 10 ACTYON 2008 01 0000 00 AIR BAG ...

Page 688: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 689: ......

Page 690: ...0 3 CCCS ACTYON 2008 01 0000 00 0000 00 CCCS 1 CCCS ...

Page 691: ...0 4 ACTYON 2008 01 0000 00 CCCS ...

Page 692: ...0 5 CCCS ACTYON 2008 01 0000 00 ...

Page 693: ...0 6 ACTYON 2008 01 0000 00 CCCS ...

Page 694: ...0 7 CCCS ACTYON 2008 01 0000 00 ...

Page 695: ...0 8 ACTYON 2008 01 0000 00 CCCS ...

Page 696: ...0 9 CCCS ACTYON 2008 01 0000 00 ...

Page 697: ...0 10 ACTYON 2008 01 0000 00 CCCS ...

Page 698: ...0 11 CCCS ACTYON 2008 01 0000 00 ...

Page 699: ...0 12 ACTYON 2008 01 0000 00 CCCS ...

Page 700: ...0 13 CCCS ACTYON 2008 01 0000 00 ...

Page 701: ...0 14 ACTYON 2008 01 0000 00 CCCS ...

Page 702: ...0 15 CCCS ACTYON 2008 01 0000 00 ...

Page 703: ...0 16 ACTYON 2008 01 0000 00 CCCS ...

Page 704: ...0 17 CCCS ACTYON 2008 01 0000 00 ...

Page 705: ...0 18 ACTYON 2008 01 0000 00 CCCS ...

Page 706: ...0 19 CCCS ACTYON 2008 01 0000 00 ...

Page 707: ...0 20 ACTYON 2008 01 0000 00 CCCS ...

Page 708: ...0 21 CCCS ACTYON 2008 01 0000 00 ...

Page 709: ...0 22 ACTYON 2008 01 0000 00 CCCS ...

Page 710: ...0 23 CCCS ACTYON 2008 01 0000 00 ...

Page 711: ...0 24 ACTYON 2008 01 0000 00 CCCS ...

Page 712: ...0 25 CCCS ACTYON 2008 01 0000 00 ...

Page 713: ...0 26 ACTYON 2008 01 0000 00 CCCS ...

Page 714: ...0 27 CCCS ACTYON 2008 01 0000 00 ...

Page 715: ......

Page 716: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 717: ......

Page 718: ...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 719: ...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 720: ...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 721: ...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 722: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 723: ......

Page 724: ...0 3 FFH ACTYON 2008 01 0000 00 0000 00 FFH 1 FFH ...

Page 725: ...0 4 ACTYON 2008 01 0000 00 FFH ...

Page 726: ...0 5 FFH ACTYON 2008 01 0000 00 ...

Page 727: ...0 6 ACTYON 2008 01 0000 00 FFH ...

Page 728: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 729: ......

Page 730: ...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 731: ...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 732: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 733: ......

Page 734: ...0 3 STICS ACTYON 2008 01 0000 00 0000 00 STICS 1 STICS ...

Page 735: ...0 4 ACTYON 2008 01 0000 00 STICS ...

Page 736: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 737: ......

Page 738: ...0 3 TC ACTYON 2008 01 0000 00 0000 00 TC 1 TC ...

Page 739: ...0 4 ACTYON 2008 01 0000 00 TC ...

Page 740: ...0 5 TC ACTYON 2008 01 0000 00 ...

Page 741: ...0 6 ACTYON 2008 01 0000 00 TC ...

Page 742: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 743: ......

Page 744: ...0 3 TCU ACTYON 2008 01 0000 00 0000 00 TCU 1 TCU ...

Page 745: ...0 4 ACTYON 2008 01 0000 00 TCU ...

Page 746: ...0 5 TCU ACTYON 2008 01 0000 00 ...

Page 747: ...0 6 ACTYON 2008 01 0000 00 TCU ...

Page 748: ...0 7 TCU ACTYON 2008 01 0000 00 ...

Page 749: ...0 8 ACTYON 2008 01 0000 00 TCU ...

Page 750: ...0 9 TCU ACTYON 2008 01 0000 00 ...

Page 751: ...0 10 ACTYON 2008 01 0000 00 TCU ...

Page 752: ...0 11 TCU ACTYON 2008 01 0000 00 ...

Page 753: ...0 12 ACTYON 2008 01 0000 00 TCU ...

Page 754: ...0 13 TCU ACTYON 2008 01 0000 00 ...

Page 755: ...0 14 ACTYON 2008 01 0000 00 TCU ...

Page 756: ...0 15 TCU ACTYON 2008 01 0000 00 ...

Page 757: ...0 16 ACTYON 2008 01 0000 00 TCU ...

Page 758: ...0 17 TCU ACTYON 2008 01 0000 00 ...

Page 759: ...0 18 ACTYON 2008 01 0000 00 TCU ...

Page 760: ...0 19 TCU ACTYON 2008 01 0000 00 ...

Page 761: ......

Page 762: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 763: ......

Page 764: ...0 3 TGS LEVER ACTYON 2008 01 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 765: ...0 4 ACTYON 2008 01 0000 00 TGS LEVER ...

Page 766: ...0 5 TGS LEVER ACTYON 2008 01 0000 00 ...

Page 767: ...0 6 ACTYON 2008 01 0000 00 TGS LEVER ...

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